Manipulacion de Cables - Compendio

PREFACIO
Durante el perodo entre junio de 1998 y julio 2001, en las minas de Queensland, de todos
los accidentes e incidentes reportados de carcter elctrico, aproximadamente el 20%
estaban relacionados con el arrastre de cables. 7% de los incidentes se relacionaron con el
arrastre de cables en minas de carbn subterrneas y con un riesgo de explosin, mientras
3% de los incidentes implic la liberacin incontrolable de energa en cables de arrastre.
Haba 34 incidentes informados donde se presentaron arcos elctricos expuestos.
El Departamento de NSW de Recursos Naturales, con la cooperacin de empresas
reparadoras de cables aprobadas, reuni datos sobre daos en los cables de arrastre
instalados en zonas de peligro en minas de carbn subterrneas. Los resultados para los
primeros seis meses se muestran en la siguiente tabla.
DAOS EN LOS CABLES - MINAS DE CARBON SUBTERRANEAS
01/04/2001 A 30/09/2001
Tipo de
Cable
Numero de
cables
daados
Numero de
chaquetas
daadas
Numero de
cables con
chaqueta
deslizada
Numero de
cables con
evidencia
de arco
Numero de
cables con
tierras
rotas
Minero 496 1241 6 44 15
Shuttle Car 1308 5642 58 76 156
Longwall 277 453 2 5 2
Feeder 294 264 1 5 13
Other 612 1128 8 11 25
TOTAL 2987 8728 75 141 211

El nmero promedio de arcos informados en una zona peligrosa por los cinco aos
1994/95 a 1998/1999 es 11 para un perodo de seis meses. La evidencia de arcos segn los
datos recolectados con las empresas reparadoras de cables es de 141 por el mismo
periodo.
Se debe notar que los reparadores de cable han identificado que el arco se ha contenido
dentro de la chaqueta del cable en la inmensa mayora de casos. Esto indica que el diseo
de los cables de arrastre (AS/NZS1802) utilizado en minas de carbn, es efectivo en
contener el arco. Otra estadstica interesante de los datos del dao en cables, es que para
cada cable que falla y se repara hay aproximadamente otros 3 con daos en la chaqueta.
Cada uno de stos daos en la chaqueta, inclusive pequeos agujeros, son fuente
potencial de ignicin en un ambiente de atmsfera peligrosa. Ellos representan tambin un
peligro indirecto para el personal minero de maniobra.
El fracaso del aislamiento en un cable de arrastre que opera en el frente de trabajo de una
mina de carbn subterrneo es causa potencial de una catstrofe por la ignicin del
metano y la carbonilla. Una explosin del metano o de carbonilla en una mina subterrnea
puede causar la prdida de vidas, la prdida de la mina y la prdida de ese recurso de
carbn.
Todos los mineros que manejan cables o que trabajan muy cerca de aparatos con cables
estn expuestos tambin a otros peligros; por ejemplo, el manejo manual de cables
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pesados, el contacto directo e indirecto con liberacin incontrolable de energa por
cortocircuito como resultado de trabajar con cables de arrastre daados.
Siete de los incidentes mencionados en la tabla, implicaron fallas de cortocircuito en los
enchufes, fracasando catastrficamente el enchufe debido a su desintegracin.
Afortunadamente no se presentaron heridas personales. El factor que salva en muchos
incidentes es simplemente la separacin en el tiempo y el espacio. Hay sin duda, muchos
ms incidentes no reportados que involucran a los cables de arrastre.
Los principales incidentes que implican cables de arrastre, ocultan varias causas raz,
incluyendo:
(a) El diseo inadecuado del equipo, incluyendo accesorios de cable tales como
enrolla cables y enchufes.
(b) Procedimientos de operacin y maniobra inadecuados.
(c) Fallar al no observar los procedimientos de operacin.
(d) Inadecuado mantenimiento o debilidad en el mantenimiento.
(e) La falta en la comprensin de los peligros y riesgos asociados a los cables de
arrastre.
(f) Problemas culturales y de conducta
(g) La existencia de personas que creen que algo malo no les puede suceder a ellos
o que no puede suceder en su mina
(h) La creencia de que los cables de arrastre no son un bien de capital y que deben
ser tratados como artculos desechables o consumibles.
(i) La creencia de que los cables de arrastre recibirn severos daos y que estos
daos son simplemente inevitables.
(j) Deficiente cultura en el lugar de trabajo. Por ejemplo, Nosotros siempre
daamos los cables, daar los cables se acepta como parte de la manera en que
nosotros hacemos las cosas por aqu.
(k) Procedimientos y tcnicas inadecuados para la investigacin de accidentes e
incidentes
(l) Deficiencia en sistemas y procedimientos preventivos y correctivos.
(m) Fallar en no observar las especificaciones de los fabricantes y sus criterios de
diseo; por ejemplo, La operacin contina dentro del radio de mnimo de
curvatura permisible del cable.

Se requiere un cambio significativo del paradigma con respecto a la manera en que se
arrastran los cables y se manejan los riesgos y de cmo el resultado involucra la
productividad y seguridad en las minas. Estas lneas procuran proporcionar una gua en la
administracin de estos asuntos con miras a proporcionar un proceso de cambio para
llevar al mximo la vida de cable y aminorar los riesgos en la operacin del mismo.

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AUSPROOF
manipulacin de cables energizados
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Objetivos
Objetivos
Incrementar las horas operativas

Incrementar las horas operativas
-
-
maquina.
maquina.
Disminuir los actos inseguros.

Disminuir los actos inseguros.
Disminuir los da
Disminuir los da
os con o sin perdidas.

os con o sin perdidas.
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Analizando
Analizando
la situaci
la situaci
n
n
Tenemos una flota de 4 palas y 3 perforadoras con 48 cables de a Tenemos una flota de 4 palas y 3 perforadoras con 48 cables de arrastre en servicio. Se rrastre en servicio. Se
sabe que anualmente se compran 8 cables de arrastre por reposici sabe que anualmente se compran 8 cables de arrastre por reposici n. n.
Significa que el 17% de la instalaci Significa que el 17% de la instalaci n es renovada anualmente o lo que es lo mismo, que n es renovada anualmente o lo que es lo mismo, que
la vida la vida til de los cables en esta mina es de aproximadamente 5.8 a til de los cables en esta mina es de aproximadamente 5.8 a os. os.
Se sabe que los cables de arrastre mineros pueden llegar hasta l Se sabe que los cables de arrastre mineros pueden llegar hasta los 20 a os 20 a os en servicio os en servicio
confiable y seguro; siempre y cuando, la mina aplique buenas pra confiable y seguro; siempre y cuando, la mina aplique buenas practicas de manipulaci cticas de manipulaci n n
en los cables de arrastre. en los cables de arrastre.
Supongamos que la implementaci Supongamos que la implementaci n de un sistema de administraci n de un sistema de administraci n de cables de arrastre n de cables de arrastre
en la mina del ejemplo alcanzo en el primer a en la mina del ejemplo alcanzo en el primer a o de su implementaci o de su implementaci n solo el 60% de sus n solo el 60% de sus
objetivos (ignoremos a Pareto ); esto no solo significa que la v objetivos (ignoremos a Pareto ); esto no solo significa que la vida en servicio de los cables ida en servicio de los cables
alcanzo los 7 a alcanzo los 7 a os y que redujo la reposici os y que redujo la reposici n a 4.8 cables anuales, si no que tambi n a 4.8 cables anuales, si no que tambi n, n,
redujo los actos inseguros al 60% del valor original ( recordemo redujo los actos inseguros al 60% del valor original ( recordemos el triangulo de Bird ). Por s el triangulo de Bird ). Por
lo tanto, no solo existe la recompensa econ lo tanto, no solo existe la recompensa econ mica en la reducci mica en la reducci n de los costos, si no n de los costos, si no
tambi tambi n, la recompensa n, la recompensa tica de haber evitado fatalidades. tica de haber evitado fatalidades.
No olvidar que metas ambiciosas conllevan a resultados satisfact No olvidar que metas ambiciosas conllevan a resultados satisfactorios. Metas comunes orios. Metas comunes
desencadenan en resultados mediocres. desencadenan en resultados mediocres.
Bird Bird
Sin lesiones o da Sin lesiones o da os 600, da os 600, da os a la propiedad 30, lesiones menores o incapacitantes 10, lesi os a la propiedad 30, lesiones menores o incapacitantes 10, lesiones permanentes o fatales 1. Estudio de mas de un ones permanentes o fatales 1. Estudio de mas de un
mill mill n de accidentes fortuitos publicado en 1976. n de accidentes fortuitos publicado en 1976.
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Como
Como
Facilitando equipamiento, maquinas y

Facilitando equipamiento, maquinas y
herramientas sin
herramientas sin
rgicas con la actividad.

rgicas con la actividad.
Realizando procedimientos e instruyendo

Realizando procedimientos e instruyendo
al personal.
al personal.
Manteniendo el inter
Manteniendo el inter
s y la
s y la
responsabilidad del personal.
responsabilidad del personal.
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Maquinas, Equipamiento y
Maquinas, Equipamiento y
Herramientas Sin
Herramientas Sin
rgicas
rgicas
Generalidades de los
Generalidades de los
Cables.
Cables.
EPP especifico requerido.

EPP especifico requerido.
Maquinas requeridas.
Maquinas requeridas.
Herramientas.
Herramientas.
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Generalidades de los Cables
Un cable de alto voltaje no Un cable de alto voltaje no
apantallado, presenta distorsi apantallado, presenta distorsi n en n en
sus l sus l neas de flujo del campo neas de flujo del campo
magn magn tico ( energ tico ( energ a electrost a electrost tica ) tica )
cuando es instalado en las cercan cuando es instalado en las cercan as as
de un punto a tierra. Resultando en de un punto a tierra. Resultando en
una variaci una variaci n significativa de los n significativa de los
voltajes electrost voltajes electrost ticos (stress) ticos (stress)
aplicados al aislamiento. aplicados al aislamiento.
Un cable de alto voltaje apantallado, Un cable de alto voltaje apantallado,
presenta l presenta l neas de flujo del campo neas de flujo del campo
magn magn tico uniforme ( energ tico uniforme ( energ a a
electrost electrost tica ) a pesar de ser tica ) a pesar de ser
instalado en las cercan instalado en las cercan as de un as de un
punto a tierra. Resultando en una punto a tierra. Resultando en una
distribuci distribuci n homog n homog nea de los nea de los
voltajes electrost voltajes electrost ticos (stress) ticos (stress)
aplicados al aislamiento. aplicados al aislamiento.
Adobe Acrobat
Document
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Dimetros de curvatura mnima (SHD-GC en pulgadas)
Calibre
2KV 5KV 8KV 15KV 25KV
2 19 22 34 39 -
1 21 23 35 40 47
1/0 21 23 35 40 47
2/0 24 26 39 44 51
3/0 26 28 42 46 53
4/0 28 30 44 49 56
350 34 35 51 56 62
500 38 40 57 61 -
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Amperios (SHD)
Calibre
mm2 2KV 5KV 8KV 15KV 25KV
2 159 159 159 164 178
1 35 184 184 184 187 191
1/0 50 211 211 211 215 218
2/0 243 243 243 246 249
3/0 70 279 279 279 283 286
4/0 95 321 321 321 325 327
350 435 435 435 - -
500 240 536 536 536 - -
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TENSIONES MAXIMAS DEL CABLE TENSIONES MAXIMAS DEL CABLE
Aplicaci Aplicaci n n
Tipo de Cable Tipo de Cable M M xima Fuerza de xima Fuerza de
Trabajo Segura (SWF) Trabajo Segura (SWF)
N/mm2 N/mm2
Chaqueta no Chaqueta no
reforzada. reforzada.
15 15
Chaqueta Chaqueta
20 20
Chaqueta no Chaqueta no
reforzada reforzada
.
.
20 20
Chaqueta Chaqueta
30 30
Arrastre Arrastre
Enrollado Enrollado
M M xima Tensi xima Tensi n de Arrastre. n de Arrastre.
T = n T = n x x CSA CSA x x SWF SWF
Donde: Donde:
T T = = Tensi Tensi n en newtons. (N) n en newtons. (N)
N N = = Numero de conductores del cable. Numero de conductores del cable.
CSA CSA = = rea de la secci rea de la secci n transversal de los conductores. Descartar los hilos piloto, n transversal de los conductores. Descartar los hilos piloto,
pantallas y chaquetas. (mm2) pantallas y chaquetas. (mm2)
SWF SWF = = Fuerza de trabajo segura. (N/mm2) Fuerza de trabajo segura. (N/mm2)
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M M xima Longitud de Arrastre. xima Longitud de Arrastre.
L = T / (f L = T / (f x x W W x x 10) 10)
Donde: Donde:
L L = = M M xima longitud a ser arrastrada. ( xima longitud a ser arrastrada. (mts mts) )
T T = = Tensi Tensi n en newtons. n en newtons.
f f = = Coeficiente de fricci Coeficiente de fricci n entre el cable y la superficie. 0.5 n entre el cable y la superficie. 0.5
para superficies secas. Si se desea considerar el peor para superficies secas. Si se desea considerar el peor
de los casos, utilizar coeficiente de 0.7 de los casos, utilizar coeficiente de 0.7
W W = = Masa del cable en kilogramos por metro. ( Masa del cable en kilogramos por metro. (Kg Kg/ /mts mts) )
Nota: En el punto tangencial del doblez, se presentan fuerzas contrapuestas de tensin, por
lo tanto, al utilizar lazos para el arrastre de cables, se deber dividir entre 2 la
formula de mxima longitud de arrastre.
M M xima Longitud de Suspensi xima Longitud de Suspensi n. n.
L = T / (W L = T / (W x x 9.8) 9.8)
Donde: Donde:
L L = = M M xima longitud a suspender. ( xima longitud a suspender. (mts mts) )
T T = = Tensi Tensi n en newtons. n en newtons.
W W = = Masa del cable en kilogramos por metro. ( Masa del cable en kilogramos por metro. (Kg Kg/ /mts mts) )
9.8 9.8 = = Fuerza de la gravedad. Fuerza de la gravedad.
T T
2T
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CABLES, RASGOS Y CARACTER CABLES, RASGOS Y CARACTER STICAS STICAS
Rasgo Rasgo Caracter Caracter stica stica Funci Funci n n
Construcci Construcci n standard del n standard del
conductor. conductor.
Medianamente flexible y Medianamente flexible y
gran robustez. gran robustez.
Flexibilidad en el cable y Flexibilidad en el cable y
resistencia al aplastamiento. resistencia al aplastamiento.
Conductores superflexibles Conductores superflexibles Mayor flexibilidad Mayor flexibilidad Provee m Provee m nima resistencia a la nima resistencia a la
curvatura adicional a los curvatura adicional a los
menores radios de curvatura menores radios de curvatura
posibles. El conductores tiene posibles. El conductores tiene
mayor cantidad de hilos con mayor cantidad de hilos con
di di metros peque metros peque os. os.
Aislamiento Aislamiento Aislamiento de alto Aislamiento de alto
grado grado
Provee integridad el Provee integridad el ctrica al ctrica al
cable a todo lo largo de su vida cable a todo lo largo de su vida
til. til.
Pantallas semiconductoras Pantallas semiconductoras
extruidas. extruidas.
Semi conducci Semi conducci n. n. Baja resistencia a la puesta a Baja resistencia a la puesta a
tierra alrededor de cada tierra alrededor de cada
conductor lo que incrementa la conductor lo que incrementa la
performance el performance el ctrica sin ctrica sin
perjudicar la flexibilidad. perjudicar la flexibilidad.
Pantallas de metal trenzado. Pantallas de metal trenzado. Alta conductividad. Alta conductividad. Prevenci Prevenci n del riesgo al corto n del riesgo al corto
circuito, el trenzado forma una circuito, el trenzado forma una
puesta a tierra de muy baja puesta a tierra de muy baja
resistencia y alta confiabilidad. resistencia y alta confiabilidad.
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Tierras intersticiales Tierras intersticiales Fortaleza mec Fortaleza mec nica nica Reemplaza las pantallas trenzadas Reemplaza las pantallas trenzadas
en cables que son frecuentemente en cables que son frecuentemente
manipulados. manipulados.
Piloto intersticial. Piloto intersticial. Piloto aislado. Piloto aislado. Los pilotos son usados para los Los pilotos son usados para los
circuitos de control. Reemplaza el circuitos de control. Reemplaza el
piloto central y permite reducir el piloto central y permite reducir el
di di metro. metro.
Tierras semiconductoras. Tierras semiconductoras. Semi conducci Semi conducci n n Presenta baja resistencia entre el Presenta baja resistencia entre el
n n cleo de una tierra y la siguiente cleo de una tierra y la siguiente
facilitando una alta conducci facilitando una alta conducci n al n al
circuito a tierra. circuito a tierra.
Soporte Central Soporte Central Soporte a los n Soporte a los n cleos. cleos. Provee soporte y protecci Provee soporte y protecci n contra n contra
el aplastamiento de los n el aplastamiento de los n cleos. cleos.
Mayormente son semi conductivos, Mayormente son semi conductivos,
por lo tanto, no permiten las fallas por lo tanto, no permiten las fallas
fase a fase sin pasar por tierra. fase a fase sin pasar por tierra.
Usualmente incorporan el piloto Usualmente incorporan el piloto
central. central.
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Piloto Central Piloto Central Extensible Extensible Provee seguridad y facilidad de Provee seguridad y facilidad de
trabajo con el cable. Tolera trabajo con el cable. Tolera
estiramientos del cable antes que se estiramientos del cable antes que se
rompa la l rompa la l nea piloto. Usado por los nea piloto. Usado por los
circuitos de monitorea para la circuitos de monitorea para la
apertura de los apertura de los seccionadores seccionadores antes antes
que el cable se rasgado por un tir que el cable se rasgado por un tir n. n.
El cable tipo 425 cuanta con 3 l El cable tipo 425 cuanta con 3 l neas neas
piloto centrales. piloto centrales.
Extrusi Extrusi n semi n semi
conductiva sobre los conductiva sobre los
conductores. conductores.
Semi conducci Semi conducci n. n. Provee una pantalla completa al cable Provee una pantalla completa al cable
conductor con una v conductor con una v a semiconductora a semiconductora
hacia los conductores a tierra. De hacia los conductores a tierra. De
presentarse alg presentarse alg n punto d n punto d bil en la bil en la
chaqueta aislante del conductor, esta chaqueta aislante del conductor, esta
falla ser falla ser puesta a tierra. puesta a tierra.
Chaqueta reforzada Chaqueta reforzada Cintas o hilos de gran Cintas o hilos de gran
fortaleza. fortaleza.
Provee fortaleza mec Provee fortaleza mec nica radial a la nica radial a la
chaqueta y al cable previniendo chaqueta y al cable previniendo
aplastamientos y deformaciones del aplastamientos y deformaciones del
cable. cable.
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EPP Requeridos
EPP Requeridos
Guantes Aislantes Guantes Aislantes
Para la manipulaci Para la manipulaci n manual n manual
de los cables. de los cables.
Evitan la electrocuci Evitan la electrocuci n del n del
personal por un deterioro de personal por un deterioro de
aislamiento en la chaqueta no aislamiento en la chaqueta no
detectado. detectado.
Herramientas
Las guardas de cuero Las guardas de cuero
incrementan la vida incrementan la vida til de los til de los
guantes aislantes y conservan la guantes aislantes y conservan la
confiabilidad del aislamiento confiabilidad del aislamiento
protector. protector.
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Maquinas Requeridas
Maquinas Requeridas
Tractor sobre orugas + Tractor sobre orugas +
aditamento manipulador de aditamento manipulador de
cables. cables.
Para el tendido y recojo de las Para el tendido y recojo de las
l l neas de alimentaci neas de alimentaci n desde y n desde y
hacia la maquinaria el hacia la maquinaria el ctrica. ctrica.
El brazo facilita el tendido en El brazo facilita el tendido en
bermas. bermas.
Moto niveladora Moto niveladora
Para el arrastre de cables bajo Para el arrastre de cables bajo
los arreglos y con las los arreglos y con las
herramientas sugeridos mas herramientas sugeridos mas
adelante. adelante.
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Maquinas Requeridas
Maquinas Requeridas
Cami Cami n manipulador: n manipulador:
Transporte del personal Transporte del personal
encargado como tambi encargado como tambi n de los n de los
patines y otras herramientas y patines y otras herramientas y
accesorios requeridos en el d accesorios requeridos en el d a a a a
d d a. a.
Puede ser habilitado para el re Puede ser habilitado para el re- -
tendido de las l tendido de las l neas de neas de
alimentaci alimentaci n desde y hacia la n desde y hacia la
pala o perforadora. pala o perforadora.
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Herramientas
Herramientas
Tambores: Tambores:
Para el transporte, tendido, recojo y Para el transporte, tendido, recojo y
almacenamiento eficiente de cables. almacenamiento eficiente de cables.
Evita exponerlos al deterioro. Evita exponerlos al deterioro.
Separaci Separaci n del enchufe para evitar el n del enchufe para evitar el
contacto de la chaqueta con las aristas contacto de la chaqueta con las aristas
de este. de este.
Pat Pat n Porta Cables: n Porta Cables:
Para el transporte eficiente de cables. Para el transporte eficiente de cables.
Evita exponerlos al deterioro. Evita exponerlos al deterioro.
Se debe utilizar el arreglo en forma de Se debe utilizar el arreglo en forma de
ocho para no alterar la h ocho para no alterar la h lice original lice original
del cable. del cable.
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Pat Pat n Jala Cables con Curva Radial: n Jala Cables con Curva Radial:
Para la reconfiguraci Para la reconfiguraci n de los n de los
tendidos de alimentaci tendidos de alimentaci n. n.
Evita exponer al cable a curvaturas Evita exponer al cable a curvaturas
excesivas que deterioran la h excesivas que deterioran la h lice y lice y
exceden los limites de tensi exceden los limites de tensi n de n de
jalado. jalado.
El largo del lazo no debe exceder los El largo del lazo no debe exceder los
30mts. 30mts. ( Cables 350 y 500MCM, 3/0 y 4/0 AWG ) ( Cables 350 y 500MCM, 3/0 y 4/0 AWG )
Herramientas
Herramientas
Pat Pat n Protector de Junta: n Protector de Junta:
Para la reconfiguraci Para la reconfiguraci n de los n de los
tendidos de alimentaci tendidos de alimentaci n energizados. n energizados.
Evita exponer la junta al deterioro por Evita exponer la junta al deterioro por
tensi tensi n, atrapamiento, falta de n, atrapamiento, falta de
visibilidad y contaminaci visibilidad y contaminaci n. n.
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Herramientas
Herramientas
Gancho para cables: Gancho para cables:
No suplen el uso de guantes de alta. No suplen el uso de guantes de alta.
Proveen ergonom Proveen ergonom a, evitando el exceso a, evitando el exceso
de flexiones, las posibles lesiones de flexiones, las posibles lesiones
lumbares y aleja al cable del cuerpo. lumbares y aleja al cable del cuerpo.
Clic aqu Clic aqu .
Eslingas & sogas: Eslingas & sogas:
No suplen el uso de guantes de alta. No suplen el uso de guantes de alta.
Permite habilitar puntos de anclaje Permite habilitar puntos de anclaje
f f cilmente. De usarse una eslinga, cilmente. De usarse una eslinga,
esta deber esta deber ser instalada en por lo ser instalada en por lo
menos dos puntos del cable, en caso de menos dos puntos del cable, en caso de
usarse sogas, se deber usarse sogas, se deber usar el nudo usar el nudo
de la fotograf de la fotograf a para incrementar el a para incrementar el
rea de contacto y disminuir el da rea de contacto y disminuir el da o o
por deslizamiento de la chaqueta. por deslizamiento de la chaqueta.
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Procedimientos e
Procedimientos e
Instrucci
Instrucci
n
n
Introducci
Introducci
n.
n.
Peligros t
Peligros t
picos y sus
picos y sus
mecanismos para su
mecanismos para su
realizaci
realizaci
n.
n.
Etapas requeridas para un

Etapas requeridas para un
sistema de administraci
sistema de administraci
n
n
de cables exitoso.
de cables exitoso.
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Introducci
Introducci
n.
n.
Los sistemas de administraci Los sistemas de administraci n de cables deben ser concebidos de tal manera que n de cables deben ser concebidos de tal manera que
eliminen, tanto como sea posible, la manipulaci eliminen, tanto como sea posible, la manipulaci n directa de los cables de arrastre n directa de los cables de arrastre
energizados. No se recomienda la manipulaci energizados. No se recomienda la manipulaci n directa de cables de arrastre a pesar que el n directa de cables de arrastre a pesar que el
dise dise o de los cables y sus accesorios proporcionan la adecuada protec o de los cables y sus accesorios proporcionan la adecuada protecci ci n al personal n al personal
contra la exposici contra la exposici n a la energ n a la energ a el a el ctrica. ctrica.
La raz La raz n de esto es que la condici n de esto es que la condici n del cable no puede ser sabida. Los da n del cable no puede ser sabida. Los da os pueden estar os pueden estar
presente antes, durante o por la manipulaci presente antes, durante o por la manipulaci n de estos. n de estos.
Las maquinas de manipulaci Las maquinas de manipulaci n, ganchos o las cuerdas aisladas, los guantes de alto n, ganchos o las cuerdas aisladas, los guantes de alto
voltaje, entre otros, se deben utilizar para proporcionar protec voltaje, entre otros, se deben utilizar para proporcionar protecci ci n adicional al operador n adicional al operador
durante la manipulaci durante la manipulaci n de los cables de arrastre energizados. Estos dispositivos no n de los cables de arrastre energizados. Estos dispositivos no solo solo
ayudan atenuando los riesgos el ayudan atenuando los riesgos el ctricos, sino que tambi ctricos, sino que tambi n, asisten al operador en su n, asisten al operador en su
trabajo manual. trabajo manual.
De ser inevitable la manipulaci De ser inevitable la manipulaci n manual de cables de arrastre energizados, es de alta n manual de cables de arrastre energizados, es de alta
recomendaci recomendaci n, proceder con un an n, proceder con un an lisis de riesgo que resulte en un procedimiento de lisis de riesgo que resulte en un procedimiento de
trabajo escrito donde los riesgos y sus controles se encuentren trabajo escrito donde los riesgos y sus controles se encuentren plenamente identificados. plenamente identificados.
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Introducci
Introducci
n.
n.
Los tiempos de vida posibles con par Los tiempos de vida posibles con par metros de seguridad y servicio confiables de los metros de seguridad y servicio confiables de los
cables de arrastre en minas a tajo abierto son: cables de arrastre en minas a tajo abierto son:
Minas a tajo abierto con buenas practicas de manipulaci Minas a tajo abierto con buenas practicas de manipulaci n y un mantenimiento regular n y un mantenimiento regular
del cable: del cable:
Cables de las bombas y perforadoras Cables de las bombas y perforadoras Hasta 20 a Hasta 20 a os. os.
Cables de palas. Cables de palas. Hasta 20 a Hasta 20 a os. os.
Cables de dragalinas Cables de dragalinas Hasta 20 a Hasta 20 a os. os.
Minas a tajo abierto sin practicas de manipulaci Minas a tajo abierto sin practicas de manipulaci n y sin un mantenimiento regular al n y sin un mantenimiento regular al
cable: cable:
Cables de las bombas y perforadoras Cables de las bombas y perforadoras De 3 a 7 a De 3 a 7 a os. os.
Cables de palas. Cables de palas. De 3 a 7 a De 3 a 7 a os. os.
Cables de dragalinas Cables de dragalinas De 3 a 7 a De 3 a 7 a os. os.
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Riesgos T
Riesgos T
picos y sus
picos y sus
Mecanismos de Realizaci
n.
n.
Algunos Riesgos Algunos Riesgos
T T picos picos
Algunos mecanismos t Algunos mecanismos t picos de realizaci picos de realizaci n n
Contacto directo con los Contacto directo con los
conductores del cable o con conductores del cable o con
los accesorios de este, tales los accesorios de este, tales
como los enchufes. como los enchufes.
Cable defectuoso con exposici Cable defectuoso con exposici n de conductores energizadas y falla de la n de conductores energizadas y falla de la
protecci protecci n en detectar la falla. n en detectar la falla.
Enchufes defectuosos exponiendo conductores energizados y l Enchufes defectuosos exponiendo conductores energizados y l neas piloto neas piloto
conectadas a bornes incorrectos, no existen o han sido eliminada conectadas a bornes incorrectos, no existen o han sido eliminadas. s.
Contacto indirecto del Contacto indirecto del
personal con un cable personal con un cable
defectuoso. defectuoso.
Falla en la protecci Falla en la protecci n y procedimientos para detectar y corregir una n y procedimientos para detectar y corregir una
falla. falla.
D D bil o carente control de procedimientos para la manipulaci bil o carente control de procedimientos para la manipulaci n de cables. n de cables.
Peque Peque os hoyos en la chaqueta posibilitando descargas superficiales. os hoyos en la chaqueta posibilitando descargas superficiales.
Inducci Inducci n de alto voltaje en la l n de alto voltaje en la l neas de bajo voltaje ( piloto o de control ) neas de bajo voltaje ( piloto o de control )
debido a la carencia de la segregaci debido a la carencia de la segregaci n de las fases por tierra. n de las fases por tierra.
Uso de cables no apantallados o que no cuentan con barreras en l Uso de cables no apantallados o que no cuentan con barreras en las fases. as fases.
( Segregaci ( Segregaci n de fases por tierra ) AS/NZS 1802 o AS/NZS 2802. n de fases por tierra ) AS/NZS 1802 o AS/NZS 2802.
Deficiente dise Deficiente dise o de puesta a tierra o la falta de limitadores de corriente o de puesta a tierra o la falta de limitadores de corriente
de falla a tierra o limitadores de falla a tierra da de falla a tierra o limitadores de falla a tierra da ados o la falta de ados o la falta de
enclavamientos mec enclavamientos mec nicos ( nicos (lock lock- -out) en la puesta a tierra. out) en la puesta a tierra.
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Riesgos T
Riesgos T
picos y sus
picos y sus
n.
n.
Explosi Explosi n de enchufes u n de enchufes u
otras descargas otras descargas
incontroladas de energ incontroladas de energ a. a.
Dise Dise o deficiente del equipamiento el o deficiente del equipamiento el ctrico complementario de los ctrico complementario de los
cables cables El El ctricamente no sim ctricamente no sim tricos. tricos.
Debilidad en el mantenimiento de los accesorios Debilidad en el mantenimiento de los accesorios electricos electricos del cable del cable
que resultan en el ingreso de humedad. que resultan en el ingreso de humedad.
Practicas de manipulaci Practicas de manipulaci n y maniobra deficientes que exponen a los n y maniobra deficientes que exponen a los
enchufes al deterioro y contaminaci enchufes al deterioro y contaminaci n n Enchufes dejados sobre la Enchufes dejados sobre la
tierra. tierra.
Da Da os en los accesorios de los cables que provocan la degradaci os en los accesorios de los cables que provocan la degradaci n del n del
aislamiento. aislamiento.
Deficiente o nula sinton Deficiente o nula sinton a de las protecciones al corto circuito. a de las protecciones al corto circuito.
Limitaci Limitaci n de las corrientes de falla a tierra inapropiada o carencia n de las corrientes de falla a tierra inapropiada o carencia
de protecciones. de protecciones.
Explosi Explosi n de gases o polvos n de gases o polvos
inflamables u otros inflamables u otros
materiales combustibles. materiales combustibles.
Inapropiadas o nulas protecciones de falla a tierra y enclavamie Inapropiadas o nulas protecciones de falla a tierra y enclavamientos ntos
mec mec nicos ( nicos (lock lock- -out) en la puesta a tierra, defectuosos o carentes. out) en la puesta a tierra, defectuosos o carentes.
Par Par metros incorrectos o pobres en los dispositivos de protecci metros incorrectos o pobres en los dispositivos de protecci n. n.
Deterioro o carencia de todos o alg Deterioro o carencia de todos o alg n dispositivo de protecci n dispositivo de protecci n, n,
Practicas de operaci Practicas de operaci n en n en reas de riesgo. Deficiencia en el monitoreo reas de riesgo. Deficiencia en el monitoreo
y control del ambiente y en la prevenci y control del ambiente y en la prevenci n de la n de la energizacion energizacion de de
aparatos automatizados. aparatos automatizados.
Descargas parciales causadas por un pobre dise Descargas parciales causadas por un pobre dise o, envejecimiento y o, envejecimiento y
contaminaci contaminaci n. n.
Costos circuitos causados por la presencia de humedad, carbonill Costos circuitos causados por la presencia de humedad, carbonilla, a,
dep dep sitos de carb sitos de carb n, los cuales degradan las propiedades aislantes. n, los cuales degradan las propiedades aislantes.
Orden y limpieza deficientes. Orden y limpieza deficientes.
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Riesgos T
picos y sus
picos y sus
n.
n.
Agresiones mec Agresiones mec nicas a los nicas a los
cables. cables.
Deficiente mantenimiento a los enrolla cables y cilindros de enr Deficiente mantenimiento a los enrolla cables y cilindros de enrollado. ollado.
Operaci Operaci n deficiente en el enrollado y desenrollado de los cables en sus n deficiente en el enrollado y desenrollado de los cables en sus
tambores. tambores.
Impactos de roca provocados por el giro del balde de Dragalinas Impactos de roca provocados por el giro del balde de Dragalinas y Palas y Palas
sobre los cables sin protecci sobre los cables sin protecci n. n.
Ca Ca das de rocas desde los taludes. das de rocas desde los taludes.
Ca Ca das a nivel durante la manipulaci das a nivel durante la manipulaci n. n.
Maquinaria circulando cerca o sobre los cables. Maquinaria circulando cerca o sobre los cables.
Operaci Operaci n del cable en o por debajo de sus valores m n del cable en o por debajo de sus valores m nimos permisibles nimos permisibles
de curvatura. de curvatura.
Amarres pobres y remolcados deficientes. Amarres pobres y remolcados deficientes.
Abrasi Abrasi n de la chaqueta por un arrastre sobre superficies cortantes o n de la chaqueta por un arrastre sobre superficies cortantes o
inadecuadas. inadecuadas.
Camiones de acarreo circulando con la tolva levantada por los pu Camiones de acarreo circulando con la tolva levantada por los puentes de entes de
cables. cables.
Da Da o muscular y/o del o muscular y/o del
esqueleto. esqueleto.
Manipulaci Manipulaci n manual de los cables y sus accesorios. n manual de los cables y sus accesorios.
Conexi Conexi n y/o desconexi n y/o desconexi n no asistida de los enchufes. n no asistida de los enchufes.
Practicas de manipulaciones no establecidas o no apropiadas. Practicas de manipulaciones no establecidas o no apropiadas.
Efectos en la salud Efectos en la salud Moler, quemar u otros mecanismos que exponen al personal. Moler, quemar u otros mecanismos que exponen al personal.
Ignorancia de los riesgos y Ignorancia de los riesgos y
peligros. peligros.
Falta de entrenamiento en trabajos de riesgo. Falta de entrenamiento en trabajos de riesgo.
Pobre actitud y/o cultura Pobre actitud y/o cultura
relacionada a la seguridad relacionada a la seguridad
Liderazgo organizacional deficiente. Liderazgo organizacional deficiente.
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Etapas Requeridas para un
Etapas Requeridas para un
Sistema de Administraci
Sistema de Administraci
n
n
de Cables Exitoso
de Cables Exitoso
Obtener la atenci
Obtener la atenci
n, inter
n, inter
s y compromiso de
s y compromiso de
la organizaci
la organizaci
n y sus trabajadores.
n y sus trabajadores.
Desarrollo de procedimientos y obtenci

Desarrollo de procedimientos y obtenci
n de
n de
herramientas y equipamiento.
herramientas y equipamiento.
Entrenamiento anual y seguimiento.

Entrenamiento anual y seguimiento.
Mantener la atenci
Mantener la atenci
n, inter
n, inter
s y compromiso.
s y compromiso.
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Obtener la atenci
Obtener la atenci
n, inter
n, inter
s y
s y
compromiso de la organizaci
n
n
y sus trabajadores
y sus trabajadores
Los trabajadores que no toman atenci Los trabajadores que no toman atenci n a los actos inseguros, dejan una trampa para sus n a los actos inseguros, dejan una trampa para sus
compa compa eros de trabajo, pues la acumulaci eros de trabajo, pues la acumulaci n de los n de los relajos relajos diarios causan los desastres. diarios causan los desastres.
Actividades sub. est Actividades sub. est ndares producen mas actividades sub. est ndares producen mas actividades sub. est ndares. ndares.
Una condici Una condici n defectuosa no detectada, no reportada y no superada puede cost n defectuosa no detectada, no reportada y no superada puede costarle un dedo arle un dedo
a un mec a un mec nico, pero en alta tensi nico, pero en alta tensi n, puede costarle la vida de un electricista. n, puede costarle la vida de un electricista.
La difusi La difusi n fotogr n fotogr fica de un accidente por electrocuci fica de un accidente por electrocuci n, es la mejor manera de obtener la n, es la mejor manera de obtener la
atenci atenci n, inter n, inter s y compromiso de la organizaci s y compromiso de la organizaci n y sus trabajadores pues: n y sus trabajadores pues:
Los receptores del mensaje observan las consecuencias reales de Los receptores del mensaje observan las consecuencias reales de los actos inseguros. los actos inseguros.
Se concluye que la muerte de un compa Se concluye que la muerte de un compa ero de trabajo es totalmente posible y que eso, ero de trabajo es totalmente posible y que eso,
me puede ocurrir a mi me puede ocurrir a mi . .
Como consecuencia, los asistentes atender Como consecuencia, los asistentes atender n con inter n con inter s y se comprometer s y se comprometer n para evitar n para evitar
la muerte de un compa la muerte de un compa ero o la suya propia. ero o la suya propia.
Adobe Acrobat
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Adobe Acrobat
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Obtener la atenci
Obtener la atenci
n, inter
n, inter
s y
s y
n
n
y sus trabajadores
y sus trabajadores
Difundir reglas b Difundir reglas b sicas en un cuadro sin sicas en un cuadro sin ptico. Una propuesta de este cuadro sin ptico. Una propuesta de este cuadro sin ptico es: ptico es:
Cuida los cables de arrastre, salvaras una vida, ! tu vida Cuida los cables de arrastre, salvaras una vida, ! tu vida . .
Cuida los cables de arrastre, salvaras un puesto de trabajo. Cuida los cables de arrastre, salvaras un puesto de trabajo.
Considera como energizado cualquier cable de arrastre. Considera como energizado cualquier cable de arrastre.
Reporta los cables defectuosos inmediatamente. Reporta los cables defectuosos inmediatamente.
Nunca uses una soga con las cables sin guantes de alta. Nunca uses una soga con las cables sin guantes de alta.
Siempre utiliza los m Siempre utiliza los m todos apropiados para cruzar los cables. todos apropiados para cruzar los cables.
Siempre utiliza procedimientos aprobados para manipular los cabl Siempre utiliza procedimientos aprobados para manipular los cables y sus es y sus
accesorios accesorios. .
Utilizar los h Utilizar los h bitos mineros a favor como medio recordatorio. Por ejemplo, una bitos mineros a favor como medio recordatorio. Por ejemplo, una etiqueta etiqueta
adhesiva para el casco. adhesiva para el casco.
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Desarrollo de procedimientos
y obtenci
y obtenci
n de herramientas y
n de herramientas y
equipamiento
equipamiento
.
.
A continuaci A continuaci n se propone un desarrollo b n se propone un desarrollo b sico de los procedimientos basados en el cuadro sico de los procedimientos basados en el cuadro
sin sin ptico anterior: ptico anterior:
1. 1.- - Considera como energizado cualquier cable de arrastre. Considera como energizado cualquier cable de arrastre.
1.1. 1.1.- - Perdida de energ Perdida de energ a en el equipo. a en el equipo.
1.1.1. 1.1.1.- - Que hacer. Que hacer.
1.1.2. 1.1.2.- - A quien llamar. A quien llamar.
2. 2.- - Reporta los cables defectuosos inmediatamente. Reporta los cables defectuosos inmediatamente.
2.1. 2.1.- - Inspecci Inspecci n de cables de arrastre. n de cables de arrastre.
2.1.1. 2.1.1.- - Que buscar y como encontrarlo. Que buscar y como encontrarlo.
2.1.2. 2.1.2.- - Que hacer. Que hacer.
3. 3.- - Nunca uses una soga con las cables sin guantes de alta. Nunca uses una soga con las cables sin guantes de alta.
3.1. 3.1.- - Manipulaci Manipulaci n y maniobras con cables de arrastre. n y maniobras con cables de arrastre.
3.1.1. 3.1.1.- - Nunca jalar mas de 30mts. Nunca jalar mas de 30mts.
3.1.2. 3.1.2.- - Como usar los aditamentos del cami Como usar los aditamentos del cami n de cables. n de cables.
3.1.3. 3.1.3.- - Veh Veh culos ligeros solo peque culos ligeros solo peque as longitudes. as longitudes.
3.1.4. 3.1.4.- - El uso de veh El uso de veh culos pesados para el arrastre requiere aprobaci culos pesados para el arrastre requiere aprobaci n n
de un supervisor. de un supervisor.
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4. 4.- - Siempre utiliza los m Siempre utiliza los m todos apropiados para cruzar los cables. todos apropiados para cruzar los cables.
4.1. 4.1.- - Como cruzar los cables. Como cruzar los cables.
4.1.1. 4.1.1.- - Los cruza cables. Los cruza cables.
4.1.2. 4.1.2.- - Veh Veh culos que pueden usar los cruza cables. culos que pueden usar los cruza cables.
4.1.3. 4.1.3.- - Ganchos para cables en cada vehiculo que ingresa a la Ganchos para cables en cada vehiculo que ingresa a la
operaci operaci n. n.
4.2. 4.2.- - Como izar los cables, como enterrarlos. Como izar los cables, como enterrarlos.
4.2.1. 4.2.1.- - Est Est ndares internacionales aplicables. ndares internacionales aplicables.
5. 5.- - Siempre utiliza procedimientos aprobados para manipular los cab Siempre utiliza procedimientos aprobados para manipular los cables y sus accesorios. les y sus accesorios.
5.1. 5.1.- - Almacenamiento de cables de arrastre. Almacenamiento de cables de arrastre.
5.1.1. 5.1.1.- - Preparaci Preparaci n de una plataforma ( n de una plataforma ( yard yard ) para cables. ) para cables.
5.1.2. 5.1.2.- - Que hacer con los cables operativos, los no operativos y con lo Que hacer con los cables operativos, los no operativos y con los s
dados de baja. dados de baja.
5.1.3. 5.1.3.- - Requerimientos para la reparaci Requerimientos para la reparaci n de cables. n de cables.
5.2. 5.2.- - Eslingas & sogas para cables. Eslingas & sogas para cables.
* Que es lo mas adecuado, sigue sin poder determinarse. * Que es lo mas adecuado, sigue sin poder determinarse.
5.2.1. 5.2.1.- - Eslingas, colocarla sobre el suelo, mover el cable sobre la Eslingas, colocarla sobre el suelo, mover el cable sobre la
eslinga. eslinga.
5.2.2. 5.2.2.- - Uso de Uso de 3/8 3/8 poly poly rope rope , es no conductiva y repelente al agua. , es no conductiva y repelente al agua.
5.2.3. 5.2.3.- - Uso de los guantes de alta. Uso de los guantes de alta.
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5.3. 5.3.- - Incrementando o disminuyendo la l Incrementando o disminuyendo la l nea en servicio. nea en servicio.
5.3.1. 5.3.1.- - Uso del manipulador de cables. Uso del manipulador de cables.
5.3.2. 5.3.2.- - Corte y reposici Corte y reposici n de energ n de energ a. a.
5.3.3. 5.3.3.- - Manipulaci Manipulaci n del cable de pala o perforadora con n del cable de pala o perforadora con
camiones y otros equipos pesados. camiones y otros equipos pesados.
5.3.4. 5.3.4.- - Manipulaci Manipulaci n del cable con camionetas. Solo peque n del cable con camionetas. Solo peque as as
longitudes. longitudes.
5.4. 5.4.- - Manipulaci Manipulaci n y maniobra de enchufes. n y maniobra de enchufes.
5.4.1. 5.4.1.- - Corte y reposici Corte y reposici n de energ n de energ a ( a ( dem 5.3.2) dem 5.3.2)
5.4.2. 5.4.2.- - Conexi Conexi n y desconexi n y desconexi n mec n mec nica. nica.
5.4.3. 5.4.3.- - Uso del pat Uso del pat n CS15. n CS15.
5.4.3.1. 5.4.3.1.- - Inspecci Inspecci n de n de pre pre- -uso. uso.
5.4.3.2. 5.4.3.2.- - Anclaje del empalme y del cable. Anclaje del empalme y del cable.
5.4.3.3. 5.4.3.3.- - Puntos de remolque. Puntos de remolque.
5.4.3.4. 5.4.3.4.- - Remolque del CS15. Remolque del CS15.
5.4.4. 5.4.4.- - Uso del pedestal RST15. Uso del pedestal RST15.
5.4.4.1. 5.4.4.1.- - Inspecci Inspecci n de n de pre pre- -uso. uso.
5.4.4.2. 5.4.4.2.- - Anclaje del empalme. Anclaje del empalme.
5.5. 5.5.- - Manipulaci Manipulaci n de cables con la pala. n de cables con la pala.
5.5.1. 5.5.1.- - Enrolla cable. Enrolla cable.
5.5.2. 5.5.2.- - Esfera. Esfera.
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5.6. Contacto directo con el cable. 5.6. Contacto directo con el cable.
5.6.1. 5.6.1.- - Contacto directo no permitido bajo ninguna Contacto directo no permitido bajo ninguna
circunstancia. circunstancia.
5.7 5.7- - Uso apropiado de los ganchos para cables. Uso apropiado de los ganchos para cables.
5.7.1. 5.7.1.- - Como usarlo. Como usarlo.
5.7.2. 5.7.2.- - Como no usarlo. Como no usarlo.
5.7.3. 5.7.3.- - Como guardarlo. Como guardarlo.
5.8. 5.8.- - Protegiendo los cables de arrastre. Protegiendo los cables de arrastre.
5.8.1. 5.8.1.- - Informaci Informaci n del fabricante. n del fabricante.
5.8.2. 5.8.2.- - Uso de bermas. Uso de bermas.
5.8.3. 5.8.3.- - Uso de conos u otros tipos de se Uso de conos u otros tipos de se alizaci alizaci n. n.
5.9. 5.9.- - Cuidados y usos de los guantes de alta. Cuidados y usos de los guantes de alta.
5.9.1. 5.9.1.- - Inspecci Inspecci n de n de pre pre- -uso. uso.
5.9.2. 5.9.2.- - Pruebas semestrales requeridas. Pruebas semestrales requeridas.
5.10. 5.10.- - Cuidados de los cables en zonas de voladura. Cuidados de los cables en zonas de voladura.
5.10.1. 5.10.1.- - Protecci Protecci n del cable por si queda enterrado. n del cable por si queda enterrado.
5.10.2. 5.10.2.- - Retiro del cable de una zona de voladura. Retiro del cable de una zona de voladura.
5.11. 5.11.- - Uso de reportes de falla, reportes de reparaci Uso de reportes de falla, reportes de reparaci n, etc. n, etc.
5.11.1. 5.11.1.- - Etiquetas Etiquetas Fuera de Servicio Fuera de Servicio
5.11.2. 5.11.2.- - Historial de Historial de Eventos del Cable Eventos del Cable
5 cap 5 cap tulos, 16 t tulos, 16 t tulos y 41 subt tulos y 41 subt tulos, de los cuales 1 titulo y 4 cap tulos, de los cuales 1 titulo y 4 cap tulos est tulos est n relacionados a los enchufes. Dime como tratas al cable y te di n relacionados a los enchufes. Dime como tratas al cable y te dir r como tratas al enchufe. como tratas al enchufe.
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Reto & Standard
Reto & Standard
Caso Mina Poli met Caso Mina Poli met lica: lica:
Entre Enero del 2003 a Mayo del 2004, se registran oficialmente Entre Enero del 2003 a Mayo del 2004, se registran oficialmente en en
la flota, 310 horas de la flota, 310 horas de Maquina no Operativa Maquina no Operativa imputables a la imputables a la
confiabilidad en el suministro de energ confiabilidad en el suministro de energ a. a. ( 17.22 horas mensuales ) ( 17.22 horas mensuales )
Se investigan las causas ra Se investigan las causas ra z y se desarrollan mejoras para z y se desarrollan mejoras para
incrementar la confiabilidad en el suministro de energ incrementar la confiabilidad en el suministro de energ a, las cuales a, las cuales
se implementaron en su totalidad en Octubre del 2004. (Migraci se implementaron en su totalidad en Octubre del 2004. (Migraci n n
hacia enchufes AusProof) hacia enchufes AusProof)
Entre Octubre del 2004 a Diciembre del 2005, se registran Entre Octubre del 2004 a Diciembre del 2005, se registran
oficialmente en la flota, 145.9 horas de oficialmente en la flota, 145.9 horas de Maquina no Operativa Maquina no Operativa
imputables a la confiabilidad en el suministro de energ imputables a la confiabilidad en el suministro de energ a. ( 10.42 a. ( 10.42
horas mensuales ) horas mensuales )
Como resultado del uso de enchufes Ausproof: Como resultado del uso de enchufes Ausproof:
Se disminuyo al 60.51% las fallas imputables al suministro de Se disminuyo al 60.51% las fallas imputables al suministro de
energ energ a. a.
Se recuperaron 81.6 horas operativas anuales de la flota. Se recuperaron 81.6 horas operativas anuales de la flota.
Cual fue la base para lograr esta mejora? Cual fue la base para lograr esta mejora?
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Reto & Standard
Reto & Standard
a) a) La mina del ejemplo ya contaba con un sistema de administraci La mina del ejemplo ya contaba con un sistema de administraci n n
de cables de arrastre. de cables de arrastre.
b) La utilizaci b) La utilizaci n de enchufes AusProof caracterizados por: n de enchufes AusProof caracterizados por:
b.1) No estar basados en el arreglo tradicional hembra b.1) No estar basados en el arreglo tradicional hembra- -macho. macho.
Minimizando las existencias y el valor de estas en sus Minimizando las existencias y el valor de estas en sus
almacenes. Incrementando la confiabilidad del suministro de almacenes. Incrementando la confiabilidad del suministro de
energ energ a al minimizar los componentes involucrados en la a al minimizar los componentes involucrados en la
conexi conexi n el n el ctrica en serie. ctrica en serie.
b.2) La segregaci b.2) La segregaci n de fases por tierra el n de fases por tierra el ctrica se conserva a todo ctrica se conserva a todo
lo largo y en toda la secci lo largo y en toda la secci n transversal de los enchufes. El n transversal de los enchufes. El
avance tecnol avance tecnol gico de los cables de fases apantalladas gico de los cables de fases apantalladas
individualmente continua sin perderse en todos los enchufes. Se individualmente continua sin perderse en todos los enchufes. Se
elimina la posibilidad elimina la posibilidad de de fallas fallas fase a fase en los enchufes. fase a fase en los enchufes.
b.3) Las descargas parciales (efecto corona) son menores a las d b.3) Las descargas parciales (efecto corona) son menores a las de un e un
tel tel fono m fono m vil. Nuestro aislamiento "no envejece vil. Nuestro aislamiento "no envejece
prematuramente prematuramente . La expectativa . La expectativa de de vida vida en servicio de nuestro en servicio de nuestro
enchufe puede ser mayor a 10 a enchufe puede ser mayor a 10 a os. os.
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Informaci
Informaci
n
n
Relacionada
Relacionada
Actual Mine Shovel Power Cable Handling Actual Mine Shovel Power Cable Handling
Techniques (by Martin Reyes de Techniques (by Martin Reyes de Goldstrike Goldstrike Mine Mine
Inc. Inc. - - Barrick Barrick) )
Portable Power Cable Use and Repercussions of Portable Power Cable Use and Repercussions of
Improper Handling ( by Mark Fuller de Improper Handling ( by Mark Fuller de
AmerCable AmerCable). ).
Guide for use of trailing and reeling cables in Guide for use of trailing and reeling cables in
mines ( by Standards Australia & Standards mines ( by Standards Australia & Standards
New Zealand ) New Zealand )
Western Mining Electrical Association ( Western Mining Electrical Association ( por por
Lynn D. Nelson, Senior Reliability Engineer, Lynn D. Nelson, Senior Reliability Engineer,
Kennecott Utah Copper ). Kennecott Utah Copper ).
Dozer cable handler 1. Dozer cable handler 1.
Dozer cable handler 2. Dozer cable handler 2.
Shovel propelling. Shovel propelling.
T T cnicas para la reparaci cnicas para la reparaci n y empalmes de n y empalmes de
cables. cables.
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SB 6
HANDLING & MANAGEMENT OF SURFACE TRAILING CABLES
1.0 Introduction
Trailing cables are utilised to supply a range of surface mining equipment including pontoon pumps, electric
drills, draglines, shovels, crib huts etc. Typical voltages for trailing cables range from 415V to 22kV. Vast
amounts of energy are carried within these cables.
High potential incidents involving trailing cables at surface mines that have occurred over the last twelve
months include:
A 6.6kV trailing cable plug developed a short circuit and completely disintegrated. This occurred after
a rainstorm. Prior to this the shovel fed by the cable had walked and the plug was left lying on the
ground in a depression where rainwater pooled. While no one was injured potential existed for serious
injury had a person been in close proximity.
When a 6.6kV cable was being moved arcing from the side of the cable was noticed. Internal insulation
had failed and external arcing occurred due to a hole in the cable outer sheath at the site of a cable
repair. Protection equipment did not operate to trip the supply.
Machine operators attempted to uncouple live 6.6kV cables. They had mistaken an energised cable for
one which had been previously isolated. Protection equipment operated to trip the supply; no one was
injured.
A trailing cable was damaged during relocation with a rubber-tyre dozer. The energised cable had
excessive mechanical strain placed upon it by the machine. Protection relays operated to de-energise
the cable supply.
A 6.6kV trailing cable was pulled from its restraining plug as the cable was towed behind a cable boat
by a dozer during a dragline relocation. Undue strain had been placed on the plug - no-one was injured.
Reports have been made to the DME of persons driving light vehicles and mobile equipment over the
top of cables.
A study of incidents reveals that the group of persons most at risk of injury from trailing cables are machine
operators as they have the highest exposure to them while they are energised.
This discussion will be limited to handling, management and general operation of the cables. It seeks to raise
awareness of the potential hazards associated with trailing cables at surface mines, principally high voltage
cables, and highlight areas where attention may be required to ensure the risks are acceptable.
2.0 Potential Hazards
Potential hazards associated with surface trailing cables include:
Uncontrolled release of energy - open arcing caused by insulation failure, explosion of equipment due
to pressure rise inside apparatus caused by insulation failure (plugs). Potential injuries include severe
burns, injuries resulting from being hit by projectiles and death. A 6.6kV dragline cable could typically
Safety Bulletin
Queensland Department of Mines & Energy, Safety & Health Division,
Mines Inspectorate GPO Box 194, BRISBANE Q 4001
Ph 07 3237 1622 Fax 07 3237 1242
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contain enough energy to light 112,000 40W light bulbs. The pictures below depict a bolted 3-phase
short circuit simulated inside a trailing cable plug and facial burns received from an energy release
incident involving high voltage trailing cables.
Indirect contact of a person with electricity - a person receives an electric shock not because they touch
a live conductor, but because they touch a part that has become energised under fault conditions. An
example of this would be a person receives an electric shock after they touch the outer sheath of a
cable. The shock was received because of leakage current to the outer sheath due to insulation failure.
Potential injuries include electric shock, burns and death.
Direct contact of a person with electricity - a person touches an energised conductor in the cable. An
example of this would be a person coming into contact with the receptacles inside an energised plug or
touching a conductor inside the cable after it has been damaged. The photographs below depict burn
injuries sustained after direct contact was made with power conductors in a high voltage trailing cable.
Potential injuries include electric shock, burns and death.
Fire - the cable catches fire after a fault on the cable. Other equipment or the surrounding environment
subsequently catches fire.
Internal Energy Sources - biomechanical energy; ie. excessive forces placed on the body through
manual tasks. Potential injuries include sprains strains and permanent disablement.
3.0 Potential Risks
While the photographs above are graphic, given normal operating conditions, the risks posed to a person by an
energised trailing cable are low, however if the balance is shifted through:
Inappropriate work practice;
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Poor maintenance and repair standards;
Inappropriate selection for use; or
Inappropriate operational standards and practice.
- Then the risks may become unacceptable!
Injury, equipment damage or near hits may result, results depicted in the photographs may occur.
Any incidents, damage or injury are all indicators that the risks are not being managed
as they should!
4.0 Typical Surface Trailing Cable Construction
The diagrams below depict a typical high voltage trailing cable used to supply a dragline or shovel.
The design of the cable is such that an earth barrier is placed between the conductors. This is to ensure
that under fault conditions an earth fault will occur first thus ensuring the potential amount of energy
released is reduced compared to a power conductor to power conductor fault (phase to phase). There is
about 10mm distance between the outside of the sheath and the power conductor in a 120mm-sq. cable.
Major components of the cable and their function are as follows:
Power Conductor Copper stranded and bundled conductors that deliver the energy to where it is
required to be used. In a 120-mm sq. conductor they would be 15.6mm in diameter.
Power Conductor Insulation A rubber type insulating compound designed to contain the voltage to
the confines of the power conductor.
Cradle Separator A cradle that carries the pilot wire at its center. The cradle holds the power
conductors in their desired form and constitutes the basis of forming the cable during manufacture.
Earth Metallic Screens These screens completely surround each power conductor and are intended to
carry fault current. They constitute the cable earth.
Pilot Wire a small conductor at the very center of the cable intended to be used in conjunction with
protection relays to detect cable breakage during operation or prior to operation. The relay used will
cause power to be de-energised in the event of cable breakage or plug separation while the cable is
powered, or prevent power up if plugs are separated or the cable is broken (pilot wire broken).
Sheath a tough durable, hard wearing material designed to separate the power conductors from the
external environment and allow the cable to operate and withstand physical and environmental
conditions, which it was designed to endure.
Semi-conductive tape is used to separate the power conductors from the insulation and the insulation
from the earth screens in cables with a higher voltage rating than 3.3kV. In cables with a lower voltage
rating different materials are used for these barriers.
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Metallic Screens
Metallic Screens
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10 mm
Outer Sheath
(Insulation)
Conductor Screen
(Copper)
Inner Sheath (Insulation)
Conductor Insulation (About 4mm)
Strengethening
Mesh (Plastic)
Cable
Conductor
Conductive Rubber
Pilot Cradle
Pilot Conductor
& Pilot Insulation
Typical Surface Trailing Cable Construction
(Type 409, 6.6kV, 120 sq. mm Conductors 100mm Diameter)
5.0 Typical Sources of Cable Damage
Typical sources of cable damage include:
Machinery Damage - Machinery driving over cables including dozers, graders, light vehicles and
equipment being towed across cables e.g. Lighting plants;
Machinery Damage - Machinery striking cables, e.g. Grader blades, trucks striking cables with their
bodies up as they cross beneath bridges;
Machinery Damage Draglines set shoes down on cable, draglines/drills/shovels propel over cable;
Falling Rocks Strike and Damage Cable - Rocks from spoil piles, Falling rocks from buckets being
swung over cables;
Excessive Mechanical Strain Too much cable attempted to be pulled in one drag, cables get caught
on objects such as rocks and tear;
Exceeding Minimum Bending Radius - Cables are only designed to be bent so far (check
manufacturers guidelines for specifics);
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Wear Damage to Plugs Wear to plugs and cable chaffing from being towed;
Water Ingress into Plugs - Resulting from damaged plug seals or plugs left on the ground;
Cables Used as Scrapers - When they are being towed rocks and dirt collect at the bottom radius bends;
Poor Repair Standards Repairs fail under service conditions; and
Cable Sheaths Torn/Punctured Cable sheaths are torn and punctured by sharp objects such as rocks
and dragline tub hooks, pin holes from sharp rocks allowing water and dirt ingress.
6.0 Recommendations
6.1 Every surface mine where trailing cables are in use should develop, implement and maintain a Trailing
Cable Management System addressing the following as a minimum:
Defined selection criteria addressing the application and the intended use for trailing cables;
Defined standards for the operation of trailing cables including:
a) Regular inspection including in-situ visual inspection by machine operators;
b) Regular testing of cables and maintenance of test records, definition of cable life cycles for each
cable application and definition of measures to monitor and measure the life cycle criteria;
c) Route criteria including support measures where applicable, methods and heights for crossings,
identification measures for cables, location of cables in proximity to roadways, protection measures
required where it is necessary to swing over the top of cables, vehicle crossings etc.;
d) Methods for relocation of cables and provision of adequate equipment to perform the task, e.g.
cable reelers, relocators;
e) Assurance that repairs are performed to appropriate standards and reliable recording of a repair
history for each cable is maintained;
f) Temporary repair measures and circumstances under which they can be applied are defined;
g) Methods for manual handling are defined and provision of adequate mechanical lifting aids is
made to eliminate manual handling sprains and strains. Equipment to separate and join plugs
should be sought. Note that a 1m length of 11/11kV Type 409 cable weighs approximately 15kg;
h) Regular inspection and preventive maintenance is performed on cable accessories such as reeling
devices;
i) Regular inspection, maintenance and testing is performed on substation earth systems including
earth mats, earth impedance and earth connection points, protection relays and trip batteries;
j) Provision of unique clear identifiers for each cable and trailing cable plug and substation outlet;
k) Defined standards for the circumstances under which trailing cable protection relays can be reset
and power re-energised onto a cable where the relay has indicated a fault to be present;
l) Specific regulatory requirements are met;
m) Inspection and test procedures for equipment including earths and connections, earth
impedance, cables, substations and protection equipment after equipment relocation; and
n) Review and audit of the system.
Systems of high voltage switching, access and authorisation are developed, implemented monitored
and reviewed including the development and maintenance of statutory plans.
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Direct handling of energised cables is minimised. All persons should wear insulating gloves covered by
a leather outer when required to directly handle energised trailing cables.
Repair and testing of trailing by competent persons to AS 1747. While AS 1747 is principally a
standard for underground coal mining cables, there is no specific standard for surface cables. This
standard does describe appropriate techniques for repair and testing of surface cables. It is likely that
this standard will be revised in the future to include a separate section for repair and testing of surface
trailing cables.
Training must be provided where appropriate in the above and in trailing cable hazard awareness for all
persons required to work with them or on them. Workers associated with relevant tasks must be consulted in
relation to the development of the systems and standards mentioned above.
Rutherford Cables have kindly provided and allowed the use of the above photographs. They have developed
a Cable Hazard Awareness Training Program, which can be delivered at site. Contact Rutherfords or your
local cable repairer or manufacturer for details on any training packages that may be available.
References:
AS 1747 - Reeling, trailing and feeder cables used for mining Repair and testing
AS 2802 - Electric cables - Reeling and trailing For mining and general use (other than underground coal
mining)
Peter Minahan
Chief Inspector of Mines
SB 6, Date 19/04/2000, Contact: Robert Lewis, Inspector of Mines, 3222 2449
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Virginia Department of Mines, Minerals & Energy
Division of Mines

Accident Investigation Report
Underground Coal Mine

Electrocution Fatality
January 21, 2003

Dorchester Enterprises, Inc.
Mine No. 4
Mine Index No. 14698AA
Wise County, Virginia

CONTENTS
Photographs/Sketches . . . . . . . . . . .. . . .. . . 1-4 Conclusion . . . . . . . . . . . . . . . . . . 12
Commentary. . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Enforcement Action . . . . . . . . . . . 13-14
Statements From Mine Personnel . . . . . . . . 7-9 Recommendations . . . . . . . . . . . . 15
Physical Factors. . . . . . . . . . . . . . . . . . . . . . 9-12 Appendix . . . . . . . . . . . . . . . . . . . 16
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Fatal Accident Scene
Mine No. 4
M.I. No. 14698AA
Standing
Water
Roof Bolting
Machine Cable
Coal/Water
Slurry
Steel beam with end cut -
found lying approx. 6
from cable
Victim lying across
beam head on
right side of beam
End of steel beam that had been cut with oxygen/acetylene torches end of beam was
observed lying approx. 6 from the damaged location on the roof bolting machine cable.
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Fatal Accident Scene
Mine No. 4
M.I. No. 14698AA
Damaged Cable Insulation Roof Bolting Machine Cable
Damaged cable insulation
area cut open for inspection
Roof bolting
machine cable
Damaged power
conductor insulation
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SS # 117
Oxygen /Acetylene
Tanks
SS # 116
Oxygen/Acetylene Hoses
Heintzmann Beams
100 Ton Jackleg
Alternative Crib
Support
Trailer
(Front End)
Diesel Tractor
100 Ton Jackleg
(Horizontal)
Pump
Roof Bolting
Machine Cable
Coal Drill Cable
Continuous Mining
Machine Cable
Pump Cable
Sledgehammer
Shovel
Cut Heintzmann Beam
End of Cut Heintzmann Beam
Water line
0' 10'
Coil of Chain
Cutting Torch
Jackie Austin
Victim
FATAL ACCIDENT SCENE
Mine No. 4
January 21, 2003
Scale: 1" = 10'
SS # 120
# 5 Entry
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Jackie Austin
(Victim)
Cut Heintzmann
Beam
End of Cut
Heintzmann Beam
Roof Bolting
Machine Cable
Trailer
(Front End)
0' 3.5'
100 Ton
Jackleg
Scale: 1" = 3.5'
Alternative
Crib Support
SS # 120
FATAL ACCIDENT SCENE
Mine No. 4
January 21, 2003
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ELECTROCUTION FATALITY INVESTIGATION REPORT
DORCHESTER ENTERPRISES, INC.
MINE NO. 4
MINE INDEX NO. 14698AA

On Tuesday, January 21, 2003, at approximately 1:55 p.m., an underground electrical
power accident occurred at Dorchester Enterprises, Inc., Mine No. 4, Mine Index No. 14698AA.
Jackie Lee Austin, general laborer, employed by The New Classic Company, Inc., was fatally
injured when he apparently came in contact with a metal trailer and/or steel beams that had most
likely become energized from a damaged 440 volt alternating current (AC) roof bolting machine
trailing cable. Mr. Austin was transported to the surface and on to Wellmont Lonesome Pine
Hospital in Big Stone Gap, VA, where he was pronounced dead at 2:51 p.m. by Dr. Kenneth
Slater, emergency room phyisican. The State Medical Examiners report of autopsy indicated
low voltage electrocution as the cause of death. Mr. Austin was assisting coworkers installing
Heintzmann steel beams as supplementary roof supports on the 001 Section. Mr. Austin, age 33,
had two years total mining experience, with one year employment for The New Classic
Company, Inc. The Department of Mines, Minerals and Energys Division of Mines was
notified of the accident at approximately 2:30 p.m. on January 21, 2003, and a joint investigation
with the Federal Mine Safety and Health Administration was initiated the same day. The mine is
scheduled to receive two regular inspections every six months. The last regular inspection had
been completed on December 18, 2002.

COMMENTARY

Dorchester Enterprises, Inc., Mine No. 4, is located near Stonega, off State Route 78
North, in Wise County, Virginia. This underground mine is a one-section drift mine developed
approximately 1,850 feet in the Imboden coal seam. Approximately 1,200 tons of raw coal are
produced daily using continuous mining methods. Mining personnel produce coal on the first
and third shifts with maintenance work performed on the second shift.

The New Classic Company, Inc., is an independent contracting company employed by
Cumberland Resources Corporation to perform both underground and surface work at their
mining operations located in Virginia and Kentucky. Dorchester Enterprises, Inc., Mine No. 4, is
a subsidiary of Cumberland Resources Corporation. Mr. Austin and four other construction
general laborers, employed by The New Classic Company, Inc., were performing underground
work when the accident occurred.

On Tuesday, January 21, 2003, eleven mining personnel employed by Dorchester
Enterprises, Inc., Mine No. 4, supervised by Mr. Michael Bowman, section mine foreman,
arrived on the 001 section at approximately 7:30 a.m. to produce coal. The area where coal was
being produced was located inby from where the accident occurred. Coal production proceeded
normally during the shift until the accident occurred involving Mr. Austin. The construction
general laborers entered the mine at approximately 7:15 a.m. under the direction of Mr. John
Stewart, Jr., Contractor Supervisor. Mine management personnel had directed Mr. Stewart and
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his employees to install Heintzmann steel beams as supplemental roof supports in the No. 5
entry, near survey station number 120, at areas identified by mine management personnel. These
beams were transported on a four-wheel, rubber tire, metal trailer pulled by an A.L. Lee, Mini
Trac II, diesel powered tractor. The beam installation process involved placing the beams
against the mine roof with steel jacks installed underneath each end of the beams. Some beams
were too long to be properly installed and were required to be cut with an oxygen/acetylene
torch.

At approximately 12:15 p.m., Mr. Gail Kiser, General Mine Manager, arrived at the
location where the steel beams were being installed. Mr. Kiser and Mr. Stewart were evaluating
and discussing locations where additional roof supports would be installed. Mr. Stewart and the
construction general laborers consisting of Mr. Austin, Mr. John Osborne, Mr. Jason Johnson
and Mr. Samuel Sanders had installed five beams and were making preparations to install the
sixth beam, at approximately 1:50 p.m.

The mine floor where the beams were being installed was wet, muddy and had standing
water ranging from zero to eight inches in depth throughout the work area. Mr. Osborne had
previously cut the metal legs to the proper length necessary to install the sixth beam. At this
time, seven beams were lying in the metal trailer. Mr. Austin, Mr. Osborne, Mr. Johnson and
Mr. Sanders positioned a beam diagonally across the top of the trailer with one end lying on the
mine floor in preparation for cutting to the proper length. Mr. Osborne raised the end of the
beam, supported it on one leg and cut approximately three feet off the beam and lowered this cut
end onto the mine floor. Mr. Austin and Mr. Osborne, with assistance from Mr. Johnson and Mr.
Sanders, planned to lift and install the cut beam onto the metal legs. Mr. Osborne walked around
to the front of the trailer preparing to assist in lifting one end of the beam and expecting Mr.
Austin to lift the cut end of the beam. Mr. Johnson walked around to the front of the trailer and
touched a steel beam lying on the trailer a few seconds after the beam was cut and felt a
tingling sensation of electricity and jerked back. Mr. Austin was holding the cut-off section of
the beam that was later observed lying on the rear of the trailer during the investigation. Mr.
Osborne walked to the front of the trailer and turned toward Mr. Sanders to ask for his assistance
in lifting the beam when he heard Mr. Austin, located at the rear of the trailer, grunt twice and
say Oh God. Then Mr. Osborne turned toward the rear of the trailer and saw Mr. Austin
falling forward, face down, across the ends of the six beams that were extending from the rear of
the trailer. Mr. Osborne ran down the outby side of the trailer and across the beam that had been
cut to Mr. Austins location and touched him in an attempt to evaluate his condition. Mr.
Osborne stated that he received an electrical shock when he touched Mr. Austin and jerked back,
breaking contact with Mr. Austin. Then, Mr. Osborne stated that he said boys, hes getting
electrocuted. Mr. Osborne touched Mr. Austin a second time and received a second electrical
shock. At this time, Mr. Kiser heard Mr. Osborne call for assistance and he ran by the front and
down the outby side of the trailer and across the beam that had been cut to Mr. Austins location.
Mr. Kiser, assisted by Mr. Osborne and Mr. Stewart, rolled Mr. Austin off the beams onto the
mine floor. Mr. Osborne said that he felt a tingle of electricity, while Mr. Kiser and Mr.
Stewart said that they didnt feel any electricity as the three of them were rolling Mr. Austin off
the beams onto the mine floor. Mr. Stewart conducted a patient assessment and determined that
Mr. Austin was not breathing and had no pulse and he initiated cardiopulmonary resuscitation.
Realizing that personnel with advanced first aid knowledge and skills were needed, Mr. Kiser
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traveled to the 001 Section working places to summons Emergency Medical Technicians
(EMTs) and Advanced First Aid certified personnel. Mr. Bowman and Mr. David Aistrop,
certified as Emergency Medical Technician First Responders and Mr. Bobby Wise, certified in
Advanced First Aid, responded immediately to the accident scene and assisted Mr. Stewart and
other mine personnel in administering cardiopulmonary resuscitation. Mr. Kiser instructed Mr.
Sammy Stallard, electrical repairman, to go to the section mine telephone and to inform Mr.
Frank Bowman, mine superintendent, located on the surface, of the accident and to request
rescue squad assistance.

Mining personnel and Mr. Austins coworkers continued cardiopulmonary resuscitation
while they stabilized him on a spineboard. Cardiopulmonary resuscitation was continued while
transporting Mr. Austin to the surface. Upon arrival on the surface, Appalachia Rescue Squad
personnel assumed control and transported Mr. Austin to the Wellmont Lonesome Pine Hospital
in Big Stone Gap, VA, where he was pronounced dead at 2:51 p.m. by Dr. Kenneth Slater,
emergency room physician.

STATEMENTS FROM MINE PERSONNEL AND OTHER FACTORS:
Statements from mine personnel and other factors determined during the investigation
revealed the following:

1. The accident occurred on January 21, 2003, at approximately 1:55 p.m. in the last open
crosscut between No. 4 and No. 5 entries, approximately 18 feet from survey station
number 120, located on the 001 Section.

2. Dorchester Enterprises, Inc., Mine No. 4, is a subsidiary of Cumberland Resources
Corporation.

3. The New Classic Company, Inc. is an independent company contracted by Cumberland
Resources Corporation to perform both underground and surface work at their mining
operations located in Virginia and Kentucky.

4. The New Classic Company, Inc. employees including Mr. Stewart, Contractor
Supervisor, and four construction general laborers had been instructed to install
Heintzmann steel beams as supplemental roof supports in the face area of No. 5 entry
near survey station number 120 on the 001 Section.
5. There were no eyewitnesses to the accident; however, four other construction co-workers
and one Cumberland Resources Corporation employee were located in the general
vicinity when the accident occurred.

6. Mr. Stewart and the construction general laborers had installed five steel beams and had
prepared the sixth beam for installation when the accident occurred.

7. The construction general laborers positioned the sixth beam diagonally across the top of
the metal trailer with one end lying on the mine floor. Mr. Austin and coworkers were
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in direct contact with the beams and trailer while positioning the beam for cutting and
none of them felt any sensation of electricity. Mr. Osborne stated that he cut three feet
off the beam approximately 30 seconds before the accident occurred.

8. Mr. Osborne stated that after cutting the beam he walked to the front of the trailer to
position himself to help lift one end of the beam into position for installation. Mr.
Austin planned to lift the cut end of the beam.

9. Mr. Johnson stated that he walked around to the front of the trailer and touched a steel
beam lying on the trailer a few seconds after the beam was cut, but before the accident
occurred, and felt a tingling sensation of electricity and jerked back.

10. Mr. Osborne stated that Mr. Austin was holding the three-foot beam section that had
been cut off and walked around to the rear of the trailer. During the investigation, this
piece was observed lying on the rear of the trailer. No eyewitnesses saw Mr. Austin
place the cut off section of steel beam on the trailer.

11. Mr. Osborne stated that he turned toward Mr. Sanders to ask for help in lifting the beam
when he heard Mr. Austin, located at the rear of the trailer, grunt twice and say Oh
God. At this time, Mr. Osborne ran to Mr. Austins location and touched him in an
attempt to evaluate his condition. Mr. Osborne stated that he felt an electrical shock
when he touched Mr. Austin. After feeling an electrical shock, Mr. Osborne broke
contact with Mr. Austin. At this time, Mr. Osborne stated that he said boys, hes
getting electrocuted. Mr. Osborne stated that he touched Mr. Austin a second time and
received a second electrical shock and again broke contact.

12. Mr. Osborne and Mr. Kiser stated that they ran down the outby side of the trailer and
across the cut off end of the beam while traveling to Mr. Austins location when the
accident occurred.

13. Mr. Osborne stated that he felt a tingle of electricity while Mr. Stewart and Mr. Kiser
stated that they didnt feel any electricity as the three of them were rolling Mr. Austin off
the beams onto the mine floor. Mr. Stewart and Mr. Kiser stated that they were wearing
rubber boots and Mr. Osborne stated that he was wearing leather boots and that his feet
were wet.

14. Mr. Kiser, Mr. Stewart and Mr. Osbornes recollection of the sequence of events
differed, in that each stated that he was the first person to touch Mr. Austin after the
accident.

15. Mr. Stewart stated that while assisting with cardiopulmonary resuscitation he observed a
trailing cable in the immediate area where Mr. Austin was being treated. Mr. Stewart
also observed the cut end of the beam lying over but not in direct contact with the
trailing cable. This trailing cable was later identified as the 480 volt, three phase,
alternating current power source for the section No. 1 roof bolting machine, and it was
determined during the investigation that the cable was energized when the accident
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occurred. Mine personnel also stated that they observed the cable underneath the beam
approximately six inches from where the beam contacted the mine floor.

16. Mr. Kiser, Mr. Stewart and others stated that they did not feel any electricity while
administering first aid and performing cardiopulmonary resuscitation on Mr. Austin.

17. Mr. Osborne stated that Mr. Austin was wearing leather boots and leather gloves with
cloth gloves inserted inside the leather gloves. Mr. Osborne also stated that Mr. Austin
had informed him, approximately 45 minutes before the accident occurred, that one of
his boots was leaking and that one foot was wet.

PHYSICAL FACTORS
The investigation of physical factors revealed the following:

1. The electrical accident occurred in the No. 5 entry on the 001 section, approximately
18 feet from survey station number 120.

2. The mining height was seven feet and the entry width was nineteen feet and six
inches where the accident occurred.

3. Coal/water slurry with some standing water, ranging from zero to eight inches in
depth was present throughout the work area where the accident occurred.

4. A four wheel, rubber tire, metal trailer pulled by an A.L. Lee, Mini Trac II, diesel
powered tractor was used to transport the steel beams to the 001 Section and was
observed at the accident scene. The beams were 18 feet in length. The trailer is
sixteen feet and four inches in length and four feet and six inches in width and is
equipped with side rails that result in a total trailer height of 28 inches. Beams and
jacks were observed lying on the trailer.

5. A section of steel beam, approximately three feet in length, identified as the piece
that Mr. Austin was holding, was observed lying on the rear of the trailer.

6. Oxygen/acetylene tanks that were used to cut the steel beam were observed leaning
against the inby rib near the trailer. The torches were observed lying in the trailer.

7. The beam that had been cut was observed lying partially on the trailer with the cut
end lying against the mine floor in close proximity to but not touching the 480 volt,
three phase, alternating current, No. 1 roof bolting machine trailing cable that was
energized when the accident occurred. The cut end of the beam had a jagged edge
with protruding slag that resulted from the cutting process. This cut end of the beam
had been hot when placed on the mine floor in the immediate vicinity where the
energized No. 1 roof bolting machine trailing cable was located.

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8. The walkway clearance between the trailer and outby rib was limited due to the cut
beam, installed jacks, section equipment trailing cables, waterline and a rock. Mr.
Osborne and Mr. Kiser traveled through this partially obstructed area while enroute
to Mr. Austins location after the accident occurred.

9. The No. 1 roof bolting machine was located in the No. 4 entry inby the area where
the accident occurred. A Number 2 American Wire Gauge (AWG), two kilovolt
(KV) cable provided 480 volts alternating current (AC) to the machine and was
routed through the last open crosscut between the No. 4 and No. 5 entries and down
No. 5 entry to the section power center. This energized cable was observed at the
rear of the trailer underneath the beam approximately six inches from where the
beam contacted the mine floor. The top of the cable was barely visible in the area
where the cut end of the beam contacted the mine floor due to accumulations of loose
coal and water.

10. A damaged place on the energized 480-volt, No. 1 roof bolting machine trailing
cable was observed in close proximity to but not touching the end of the beam that
had been cut. The outer insulation of the trailing cable had been ruptured and
physical damage had exposed the red phase conductor inside the cable. The
damaged place on the cable was the most likely source of electricity that could have
energized the metal trailer and beams.

11. On January 22, 2003, all circuit breakers, including the No. 1 roof bolting machine
breaker located on the Line Power, 001 Section transformer, were examined and
tested by grounding each phase supplied to each circuit breaker. All circuit breakers
and ground check monitoring circuits operated properly. No circuit breakers tripped
(de-energized) when the accident occurred indicating that none of the circuit breakers
sensed a ground fault condition that would cause the breakers to trip (de-energize).
A ground fault condition on the No. 1 roof bolting machine trailing cable could have
existed during the accident and allowed sufficient current flow to cause the
electrocution, but sufficient current was not available to activate the protective
devices, thereby de-energizing the bolting machine circuit breaker.

12. All trailing cables providing power to section mining equipment were tested for both
grounded phase and phase-to-phase conditions and no deficiencies were observed.
All trailing cable couplers were examined and tested for proper grounding and no
deficiencies were observed.

13. One circuit breaker located on the section power center provided power to a
distribution box that was the power source for three underground pump circuits. The
circuit breakers and ground check monitoring devices provided for the three pump
circuits were examined and tested and all circuits operated properly.

14. The following observations, examinations and tests were conducted on the No. 1 roof
bolting machine trailing cable:
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The cable was observed lying underneath but not in direct contact with the
cut end of the beam;
The beam was moved and placed on the trailer to gain access to thoroughly
examine the cable in the immediate area where the cut end of the beam was
observed during the investigation;
The cable was lifted off the mine floor and secured to the mine roof with
nylon ropes;
A metal water clamp was placed around the cable approximately four feet
from the area where the cut end of the beam crossed over the cable. The
clamp was utilized to measure any potential voltage within the circumference
of the cable;
A Simpson 260 voltohm meter was utilized to measure any potential voltage
by attaching one test lead to the metal water clamp and by placing the other
test lead against the mine floor (earth);
The volt-ohm meter was positioned on the alternating current (AC) function
and the 50 volts range selector scale. A measurement of 50 volts was
detected on the trailing cable outer jacket approximately two feet from the
location where the cut end of the beam crossed over top of the energized
trailing cable. A maximum of 50 volts can be detected with the meter set on
the 50 volts range selector scale;
The volt-ohm meter was then positioned on the alternating current (AC)
function and the 250 volts range selector scale. A measurement of 250 volts
was detected on the trailing cable outer jacket in the immediate area where
the cut end of the beam crossed over top of the energized trailing cable;
A small damaged place on the outer jacket of the trailing cable was identified
as a result of 250 volts alternating current measured at this location;
The trailing cable was cut open at the damaged location for further
examination which revealed the extent of the damage extended from the
outside to the inside of the cable jacket;
A section of the trailing cable outer jacket was removed at the damaged place
to evaluate the condition of the three phase power conductors. This
examination revealed damage to the insulation provided for the red phase
power conductor which had destroyed a small segment of insulation,
exposing the phase conductor;
Damage to the trailing cables outer jacket and the red phase power conductor
provided the electrical source from which 250 volts alternating current was
measured on the outer jacket with the volt-ohm meter.
A section of roof bolting machine trailing cable containing the damaged place
was sent to the Federal Mine Safety and Health Administrations Approval
and Certification Center located in Triadelphia, West Virginia, for testing.
Mr. David Creamer, Chemist of the Materials and Explosions Testing
Branch, examined and tested the section of damaged cable. Mr. Creamer
concluded that the red phase power conductor insulation had been damaged
by an external heat source.

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CONCLUSION
On January 21, 2003, at approximately 1:55 p.m., an underground electrical power
accident occurred at Dorchester Enterprises, Inc., Mine No. 4. Jackie Lee Austin, general
laborer, employed by The New Classic Company, Inc., collapsed while performing underground
construction work and was later pronounced dead at the Wellmont Lonesome Pine Hospital. The
State Medical Examiners report of autopsy indicated low voltage electrocution as the cause of
death. Mr. Austin was fatally injured when he came in contact with a metal trailer and/or steel
beams that had most likely become energized from a damaged 440 volt alternating current, roof
bolting machine trailing cable. The Investigation Team considered the following in concluding
that an electrocution occurred:
! The trailer used to transport the steel beams was moved into the area approximately two
hours before the accident occurred. Mr. Austin and coworkers were in direct contact
with the beams and trailer while positioning the beam for cutting immediately before the
accident and none of them felt any electrical shock. The accident occurred at 1:55 p.m.,
approximately 30 to 60 seconds after the steel beam was cut. A direct relationship
between cutting the beam, placing the cut end of the beam on the mine floor and the
accident appears to exist. Mr. Johnson felt a sensation of electricity on the metal
trailer/beams immediately after the beam was cut but a few seconds before the accident
occurred. One event occurred that energized the trailer frame and a separate event
occurred that removed the electrical energy from the trailer. The event that disrupted the
flow of electricity from the trailer frame was most likely due to unintentional movement
of the beam and/or cable after the accident occurred.
! A source of electricity was verified in the immediate area where the accident occurred
that could have energized the metal trailer and beams providing sufficient voltage and
current to have caused electrocution.
! The mine floor where the accident occurred was wet, muddy and had standing water
ranging from zero to eight inches in depth throughout the work area.
! The State Medical Examiners report of toxicological analysis did not indicate any
abnormalities that contributed to Mr. Austins death.
! Mr. Austin was wearing leather boots and he had informed Mr. Osborne that one boot
was leaking and that one foot was wet approximately 45 minutes before the accident
occurred. A wet, leather boot could have provided a low resistance path to ground
potential for electricity to flow through Mr. Austin. Mr. Austin was wearing leather
gloves with cloth gloves inserted inside the leather gloves.
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ENFORCEMENT ACTION
The following enforcement action with Dorchester Enterprises, Inc., Mine No. 4, was
taken as a result of the investigation:

1. An order of closure, No. FXL0002695, was issued under section 45.1-
161.91.A.(ii) of the Coal Mine Safety Laws of Virginia to control and preserve
the scene of the accident pending the investigation. The order of closure was
modified to allow power circuits to be energized and normal mining operations to
resume.

2. * A notice of violation, number FXL0002707, was issued under section 45.1-
161.206 of the Coal Mine Safety Laws of Virginia. The investigation of the death
of a miner was conducted by the Department of Mines, Minerals and Energy and
the Federal Mine Safety and Health Administration on January 21 and 22, 2003,
at Dorchester Enterprises, Inc., Mine No. 4. Mining personnel and/or independent
contractor personnel stated in investigation interviews conducted on January 22,
2003, that an A.L. Lee, Mini-Trac II, non-permissible unit of diesel equipment,
serial No. 01-1402, had been operated in the last row of open crosscuts between
the No. 4 and No. 5 entries on the 001 section on January 21, 2003. This
violation did not contribute to the fatal accident.

3. * A notice of violation, number FXL0002709, was issued under Section 45.1-
161.207.B. of the Coal Mine Safety Laws of Virginia. The investigation of the
death of a miner was conducted by the Department of Mines, Minerals and
Energy and the Federal Mine Safety and Health Administration on January 21 and
22, 2003, at Dorchester Enterprises, Inc., Mine No. 4. Mining personnel and/or
independent contractor personnel stated in investigation interviews conducted on
January 22, 2003, that a test for methane gas had not been conducted prior to
igniting oxygen/acetylene torches used to cut metal beams in the immediate area
of survey station number 120 on the 001 section on January 21, 2003. This
violation did not contribute to the fatal accident.

4. A notice of violation, number FXL 0002705, was issued under section 45.1-
161.194.F. of the Coal Mine Safety Laws of Virginia. The investigation of the
death of a miner was conducted by the Department of Mines, Minerals and
Energy and the Federal Mine Safety and Health Administration on January 21 and
22, 2003, at Dorchester Enterprises, Inc., Mine No. 4. The trailing cable
supplying power to the No. 1 Fletcher roof drill, Serial No. 20002-022, located on
the 001 section in the immediate area of survey station number 120, was not
protected against mechanical injury. On January 22, 2003, at approximately 9:35
a.m., a damaged place was detected in the trailing cables outer jacket and the
insulation provided for the red phase conductor. The damaged place observed on
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the trailing cable and the red phase conductor insulation was located in the
vicinity where the death of a miner had occurred on January 21, 2003, at
approximately 1:55 p.m. At the location where the trailing cable was damaged, a
Department of Mines, Minerals and Energy Technical Specialist/Electrical
(certified electrical repairman), using a Simpson 260 volt-ohm meter, measured
250 volts alternating current between the outer jacket of the cable and the earth.

* Also issued to The New Classic Company, Inc.

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RECOMMENDATIONS:

1. Recognize the potential hazards created when work activities are being conducted
around electrical cables.

2. Trailing cables shall be protected against mechanical injury by hanging to the mine
roof or by location to prevent damage from equipment or other work being performed
in the affected area.

3. Miners should immediately de-energize power to any equipment or cable when stray
electrical current is detected. This hazardous condition should be reported to the
foreman and electrical repairman immediately.

4. Miners should wear rubber gloves when handling any type of energized low and
medium voltage cables. Rubber boots provide additional protection and should be
worn when practical.

5. The foreman and repairman should ensure that reports of damaged cables are checked
and corrected immediately.

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SIGNATURE SHEET

This report hereby submitted by Forrest Lambert, Jr. and approved by Frank A. Linkous:

________________________________________________________________________
FORREST LAMBERT, JR., COAL MINE INSPECTOR Date

________________________________________________________________________
FRANK A. LINKOUS, CHIEF Date

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APPENDIX

VICTIM DATA SHEET
PERSONS PRESENT DURING THE INVESTIGATION
MINE LICENSE INFORMATION

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VICTIM DATA SHEET

Name: Jackie Lee Austin
Occupation: General Laborer
Mailing Address: P. O. Box 1047, Castlewood, VA 24224
Date of Birth: February 7, 1969
Total Mining
Experience: Two years
Experience with Present Company: One year
Experience in Present Occupation: One year

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PERSONNEL

The following personnel provided information and/or were present during the
investigation:

Dorchester Enterprises, Inc., Mine No. 4

Frank Bowman Mine Superintendent
Michael Bowman Section Mine Foreman
Bobby Wise, Jr. Continuous Mining Machine Operator
Sammy Stallard Electrical Repairman
David Aistrop Shuttle Car Operator
Jeffrey Whisman Chief Electrician

The New Classic Company, Inc.

John Brady Stewart, Jr. Contractor Construction Supervisor
John Thomas Osborne General Laborer
Jason Scott Johnson General Laborer
Samuel Cleo Sanders General Laborer

Cumberland Resources Corporation

Gail Kiser General Mine Manager
Thomas Asbury Safety Director

Cumberland Resources - Electrical Consultant

Hershel Bull

Federal Mine Safety and Health Administration

Benjamin S. Harding Supervisory, Coal Mine Safety & Health Specialist,
Ventilation
Russell A. Dresch Electrical Engineer
Arnold D. Carico Mining Engineer
Larry Meade, Jr. Coal Mine Safety and Health Inspector
David Creamer Chemist, Materials and Explosions Testing Branch
Approval and Certification Center

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Virginia Department of Mines, Minerals and Energy
Division of Mines

John Thomas Mine Inspector Supervisor
Robert Garrett Coal Mine Technical Specialist - Electrical
Forrest Lambert, Jr. Coal Mine Inspector
Daniel Perkins Coal Mine Technical Specialist
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Mine License Information

Official Corporation: Dorchester Enterprises, Inc.
Official Business Name of Operator: Dorchester Enterprises, Inc.
Person With Overall Responsibility: Gail Kiser
Person in Charge of Health and Safety: Gail Kiser

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AUSPROOF
Lot 2, Callemondah Drive Gladstone Queensland Australia 4680
Ph: 61 7 49784000 Fax: 61 7 49785685 ausproof@ausproof.com.au
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Detalles de la Compaa
ABN: 17 062 940 023
Direccin: Lot 2 CallemondahDrive
GladstoneQueensland
Australia 4680
Direccin Postal: P.O. Box 1831
GladstoneDC
Australia 4680
Telefono: +61 7 49784000
Fax: +61 7 49785685
Contactos principales: PhilipMarks
Diseo & Produccin
philip@ausproof.com.au
Frank Lantry
Ventas & Mercadeo
frank@ausproof.com.au
Wendy Marks
Administracin & Logstica
ausproof@ausproof.com.au
Establecida: 1994
Ausproof, Amrica del Sur: Sergio Rogriguez Mann
sergio@ausproof.com.au
Cell: +51 1 98881503
Agente South Africa: MAE
maesa@global.co.za
AUSPROOF
AUSPROOF PTY LTD: ABN: 17 062 940 023
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HOJA RESUMEN
Fabricante de equipo original (OEM) de enchufes elctricos para cables de
arrastre y sus componentes para usuarios finales, los que incluye;
Minas de carbn a tajo abierto y socavn.
Minas poli metlicas a tajo abierto y socavn.
Perforacin de tneles.
Ausproof consiste de tres reas.
Investigacin, Diseo & Desarrollo de nuevos productos.
Fundicin no ferrosa.
Taller de maquinado bajo control numrico por computadoras (CNC)
Diseo e implementacin del desarrollo de nuevos productos es hecho por
Ausproof en su totalidad.
La excelencia de nuestro producto a sido catalogado como Clase Mundial.
Ganador de premios al diseo e innovacin patrocinados por Australasian
Institute of Mining & Metallurgy y el Qld Mining Council, en agosto del 2000.
Ganador del premio a la Innovacin.
Ganador del premio Peoples Choice.
La calidad del producto ha sido diseada para exceder los estndares
australianos e internacionales dndonos la oportunidad de exportarlo.
El diseo y manufactura de nuestro producto en permanente vanguardia
con el fin de mantener a Ausproof como el lder del mercado.
AUSPROOF
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English


ausproof@ausproof.com.au
Lot 2, Callemondah Drive
GLADSTONE. Q. 4680
AUSTRALIA
Lima Cell: (+51-1) 9 888-1503
Po. Box 1831
GLADSTONE. Q. 4680
AUSTRALIA
Fax: (+61-7) 49 785685

AusProof High Voltage Coupler for Mining Trail Cables
15000 Volts, 800Amp, IP68, Three Conductors w/Grd. Conductors & Grd. Check Conductor

Product Construction

Conductor
Alloy High Conductivity Copper 110 phase pin to
AS2738.2 and is silver plated to 10microns as per
AS1856.

Front Body, Gland Housing & Adaptor
Mounting Flange.
AluminumAlloy AA303 to Spec AS1874.

Insulation.
Phase insulators in coupler body are manufactured
fromDough Mounded Compound (DMC) with anti-
tracking materials incorporated.
Connection of the phases is by silicon rubber GP500
which compliments the anti-tracking of the DMC.
All insulating materials in accordance with S1147.1.

Sealings Rings & Connectors.
Main seal are Silicon GP500, others seals are orings
rubber.

Cable Clamps.
External clamp are AluminumAlloy AA303 to Spec
AS1874. Compression ring is rubber with copper
tighten ring.
Cable compression gland has facility to be tightened
to maintain correct pressure on cable. This can be
performed during routine maintenance and while the
coupler is energized.

Weigh.
Equipment Mount: 12.5Kg
Cable Mount: 14Kg.

Type of Coupler
15kV, 800A, IP68 bolted aluminum cable coupler
that offers a continued earth shield that segregates the
three phases and maintains the same symmetrical
radial distribution of voltage stress as in cable design.

Connection Methodology of Trailing
Cable Conductors.
Either Hexagon Crimping system or Soldered
Termination to best suit current mine practices.

Electrical Parameters

Nominal Voltage
15kV as per IEEE Std48-1996

Nominal Current
800A continuous rating as per Temperature Rise test
in accordance with AS1300 Clause 3.3.8.
20kA for 1 second short circuit (Through-fault) test.

Basic Impulse Level
95 kV BIL for 17.5 kV rms.
110kV BIL 10 positive & 10 negative as per IEEE
Std48-1996.
In addition, 95kV BIL 10 positive & 10 negative

A/C High Voltage Withstand Type Test
24kV for 1 minute.
50kV for 1 minute
35kV for 6 hours.

Through Fault Current Type Tests
20kA for 0.3 seconds
20kA for 1.0 second

Partial Discharge Type Test (Corona
effect)
10pC prior to 6 hour high voltage withstand test.
0.6pC after 6 hour high voltage withstand test.

Temperature Rise Type Test
800A Continuous

Male/Female Color Identification of
Coupler.
Not applicable. AusProof systemis a non-male/non-
female design. This enables couplers to be installed
in any location and in any orientation.

Use of Dielectric Gel Type Compound
Cable termination chamber is filled with a re-
enterable electrical resin to remove all air. The
removal of air is essential for couplers at high
altitude.

Compliances

IP68 Water proof.

CAN/ CSA M421 "the ground pin makes first and
breaks last" and the pilot pin makes last and breaks
first".

AS1300-1989 Electrical Equipment for Coal Mines
Bolted Flameproof Cable Coupling Devices.

AS/NZS1802-1992 Reeling and Trailing Electrical
Cable for Underground Coal Mining Purposes.

AS2802-1992 Electric Cables - Reeling and Trailing
for Mining and General Use.

IEEE std48-1996 Test Procedures and Requirements
for Alternating Current Cable Terminations, 2.5kV to
765kV.

AS2738.2-1984 Copper and Copper Alloys,
Compositions and Designations (Wrought Products)

AS1856-1991 Electroplated Coatings - Silver.
AS1874-1988 Aluminum and Aluminum Alloys -
Ingots and Castings.

AS1147.1-1989 Electrical Equipment for Coal Mines
Insulating Material for Insulating Power
Conducting Components.

AS1828-1984 Electrical Equipment for Explosive
Atmospheres Cable Glands.

Detailed Main Features

Air less coupler: The face profile and silicon rubber
connector expels all air when connected, eliminating
condensation, dust and corona. The cable termination
compartment is filled with re-enterable electrical
resin to remove all air.

Couplers are not based on traditional design male-
female: Diminishes existences and value of these in
your warehouse. Improve reliability on your energy
supply diminishing components involved in the
electrical connection.

Phases segregation by electrical earth is conserved
all along and in all sectional-cross of our coupler:
Technological safety improvement of cables with
individually screened phases continues without losing
in all couplers. Eliminates possibility of phase to
phase faults. Coupler does not explode, given to you,
peace of mind.

Partial discharges (crown effect) are smaller than
mobile phone: Our insulation does not age
prematurely. Expected service life of our coupler
could reach more than 10 years without incidents.
Partial discharges are smaller than 10pC as opposed
to average values of 20,000pC at common couplers.

AS WORLD CLASS
PRODUCT MUST TO BE

Main Features
Eliminating unequal electrical stresses - Matchless heat, moisture and corona resistance - Ergonometric design for
easy handling - High dielectric strength - Electrical stability under stress - Low Dielectric loss Excellent
thermal stability and electrical properties over a broad temperature range Resist impact and sunlight.
Mining Purpose Coupler
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Espaol


Email: sergio@ausproof.com.au
GLADSTONE. Q. 4680
AUSTRALIA
Lima Cell: (+51-1) 9 888-1503
Po Box 1831
GLADSTONE. Q. 4680
AUSTRALIA
Fax: (+61-7) 49 785685
Fortaleza dielctrica y altitud

Para todos es conocido que; la altitud reduce la refrigeracin convencional por aire, reduce la fortaleza dielctrica
de los terminales expuestos a la atmsfera y baja el umbral corona. Es por ello que las altitudes desde los 10.000
pies (3.048msnm), son crticas para los componentes elctricos. En conclusin, la operacin en altitud, debe ser
parte esencial en las especificaciones de la aplicacin.

Materiales gaseosos de encapsulacin:
La utilizacin de gases es conveniente pues su uso no requiere construcciones mecnicas robustas. Todos los
gases tienen conductividad termal pobre comparada con los materiales lquidos y slidos de encapsulamiento.
Los gases de mayor uso para la impregnacin aislante son el aire y el sulfuro hexafloruro. Con una constante
dielctrica cerca de 1, ambos gases tienen bajas prdidas dielctricas tanto en bajas como en altas frecuencias.
El SF
6
es una opcin frecuente en las guas de onda. En algunas ocasiones, cuando se requiere ocupar un gran
volumen, el gas se utiliza con dielctricos lquidos y/o slidos. Si el volumen extenso est situado en una regin
de esfuerzo dielctrico, las caractersticas dielctricas del gas conjuntamente con los dielctricos slidos y
lquidos presentes debern ser consideradas.

Aplicaciones que utilizan el aire circundante como medio aislante y refrigeracin:
La altitud estndar tomada para las especificaciones de los dispositivos y componentes elctricos, segn ANSI-C
37.20C e IEC 604.39-1, es por lo general 1.000msnm, En alturas ms all de los 1.000msnm, el aumento en la
temperatura de operacin y la disminucin de la fortaleza dielctrica, son una inevitable consecuencia para todos
los componentes que utilizan aire como medio aislante y de refrigeracin. Los usos en mayores altitudes
requieren por lo tanto, factores de correccin que reducen la capacidad nominal segn se muestra en la tabla.
Estos se deben aplicar para obtener valores corregidos segn la altura de la aplicacin.

Fortaleza Dielctrica Corriente nominal
1000 1.00 1.00
1500 0.95 0.99
3000 0.80 0.96
4000 0.60 nd
Nota:
Fuente: ANSI C-37.20.2, C-37.23 y C-37.30
Factores de correccin
Altura (m)
Valores intermedios pueden ser obtenidos
por interpolacion.

Por ejemplo, los factores de correccin se debern aplicar a los voltajes de impulso, voltaje nominal, corriente
nominal, etc. Para alcanzar el nivel original de la fortaleza dielctrica, el sistema de aislamiento del componente
elctrico tendr que ser mejorado en igual magnitud que la castigada por el factor de correccin. Esto se puede
lograr aumentando la separacin entre los conductores. Para alcanzar el valor original de la corriente, el tamao
de los componentes conductores deber redimensionarse para poder conducir el incremento de corriente en
proporcin con la reduccin del voltaje y/o poder disipar el calor generado.

Es menester acotar que el enchufe Ausproof no utiliza aire como medio aislante entre fases, por lo tanto, no se le
deben aplicar factores de correccin por altura.
La facilidad con la cual el aire se ioniza, hace de el un
pobre dielctrico en aplicaciones de alto voltaje. Otra
seria limitacin del aire como dielctrico, es la reduccin
de su fortaleza dielctrica con la altura. Ver figura.
El voltaje de inicio de la corona (descarga parcial) en los
dielctricos compuestos que incluyen aire, tambin
disminuye con la altura. Se concluye que el aire a
presin ambiente, no es el dielctrico ms adecuado
para aplicaciones de alto voltaje en altura.
Las caractersticas dielctricas del aire como material de
encapsulamiento se pueden mejorar si se excluye la
humedad.
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Espaol


Email: sergio@ausproof.com.au
Grados de Proteccin

Las publicaciones IEC 144 y 529, las normas NFC 20.010 de abril de 1977 y DIN 40-050 folio 1 de Agosto estn
lo suficientemente coincidentes para permitir indicar los grados de proteccin proporcionados por las envolturas
por medio de letras caractersticas IP ( ndices de Proteccin), seguidas de 3 cifras.

Ejemplo: IP559 (ver cuadro abajo para su explicacin).

Estas normas no son utilizables para la proteccin contra riesgos de explosin o condiciones tales como
humedad, vapores corrosivos, hongos o plagas.

Ciertos materiales estn destinados a ir montados en una envoltura que contribuya a darles el grado de
proteccin deseado.

Ejemplo: Unidades de mando montadas en gabinete.

En este caso, los materiales no cumplen con las normas citadas ms que cuando estn montados en las
condiciones previstas.

Las diferentes partes de un material pueden presentar unos grados de proteccin diferentes, esto de acuerdo
con las normas.

Ejemplo: Apertura en la parte inferior de un gabinete.

1.
a
cifra caracterstica 2.
a
cifra caracterstica 3.
a
cifra caracterstica

Proteccin contra los
contactos y la penetracin
de cuerpos slidos segn
IEC, NFC, DIN.

0 No protegido

1 Protegido contra
cuerpos slidos
superiores a 50mm.

2 Protegido contra
cuerpos slidos
superiores a 12mm.

3 Protegido contra
cuerpos slidos
superiores a 2,5mm.

4 Protegido contra
cuerpos slidos
superiores a 1mm.

5 Protegido contra el polvo.

6 Totalmente protegido
contra el polvo.

Proteccin contra la
penetracin de lquidos
segn IEC, NFC, DIN.

0 No protegido

1 Protegido contra las
cadas verticales de
gotas de agua.

cadas de agua verticales
(ngulo mx. 15)

3 Protegido contra el agua
de lluvia.

proyecciones de agua.

5 Protegido contra el
lanzamiento de agua.

6 Protegido contra los
golpes de mar.

7 Protegido contra los
efectos de inmersin.

8 Protegido contra la
inmersin prolongada.

Proteccin contra daos
mecnicos segn NFC.

Peso* Altura de la Energa del
cada* choque*

Kg mts. J

0 No protegido

1 0,15 0,15 0,225

2 0,15 0,25 0,375

3 0,25 0,20 0,50

5 0,50 0,40 2

7 1,50 0,40 6

9 5 0,40 20

IEC : International Electro-technical Commission.
DIN : Deutsches Institut fr Normung e. V.
NFC : New Form Code

Lima Cell: (+51-1) 9 888-1503 Fax: (+61-7) 49 785685
GLADSTONE. Q. 4680
AUSTRALIA
Po Box 1831
GLADSTONE. Q. 4680
AUSTRALIA
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Porque los cables de arrastre en
alto voltaje deberan ser
blindados.

La decisin para seleccionar cables blindados o no-
blindados para aplicaciones de arrastre en alto
voltaje, es motivo de una extensa discusin. Se debe
entender primero los principios operacionales de un
cable no-blindado en comparacin a un cable
blindado y los tipos de problemas de
funcionamiento que podran presentarse.

La funcin primaria de un conductor elctrico es
conducir voltaje y corriente. La funcin primaria de
un aislamiento es contener el voltaje dentro del
conductor. Ningn aislamiento hace esto a la
perfeccin. Todos los aislamientos presentan
acumulacin de cargas en su superficie.

El voltaje electrosttico o las tensiones, cruzan el
aislamiento y se agrupan en la superficie externa del
aislamiento intentando encontrar una trayectoria a
tierra. Estas cargas electrostticas emanan del
conductor y se llaman tensiones radiales.
Visualicemos estas lneas como los rayos de una
rueda. Idealmente, las lneas de tensin se
distribuyen uniformemente.

Las tensiones radiales en un cable de alto voltaje
no-blindado se perturban cuando el cable se coloca
en la vecindad de una superficie puesta a tierra.
(Figura 1). Esto da lugar a tensiones radiales
distorsionadas alrededor de la superficie del
aislamiento del cable. Si es el voltaje de
funcionamiento del cable es lo suficientemente alto,
por ejemplo 2400 voltios, y si el cable est en
lugares hmedos o donde la superficie del cable se
exponen a suciedad, polvo, carbonilla u otro

Figura 01

contaminante, se presentaran trayectorias de
descarga a tierra que pueden causar fallas del cable.

Un blindaje puesto a tierra alrededor de la
circunferencia del aislamiento del conductor,
distribuir uniformemente las tensiones radiales
eliminando la concentracin de tensiones y de la
ocurrencia de los voltajes superficiales. (Figura 2)
Debido a que las trayectorias de descarga a tierra, la
corona y la ionizacin no pueden ocurrir, el cable
blindado es un diseo intrnsecamente confiable,
que trabajar en todas las aplicaciones.

Blindar o no blindar, es un asunto altamente
polmico entre diseadores, ingenieros y usuarios
de cables. Existen muchas opiniones contrapuestas
sobre la necesidad de blindaje para diversas
clasificaciones de voltaje y condiciones
operacionales. Los siguientes hechos (vase al
reverso) sobre los cables no-blindados y blindados
son aceptados universalmente por los ingenieros de
cables y AmerCable.

Contina al reverso

La marca de fbrica Tigeres una marca registrada por AmerCable Incorporated
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Hay una gran probabilidad de que las tensiones
radiales que cruzan el aislamiento y se agrupan en la
superficie externa intentando encontrar una
trayectoria de descarga a tierra sean perturbadas.
Esto da lugar a una distribucin no uniforme de las
tensiones electrostticas.

La distribucin no uniforme de las tensiones
electrostticas, reduce la eficacia del aislamiento.

Si el cable entra en contacto con tierra, las
tensiones electrostticas en el punto de contacto
sern tangenciales.

Las tensiones tangenciales pueden dar lugar a;
descargas elctricas, formacin de ozono, una
fuente de ignicin para mezclas de gases
explosivos, incremento de temperatura focalizado y
deterioro general del aislamiento.

Los cables no-blindados que cruzan ambientes
hmedos y/o secos, presentaran variaciones de su
capacitancia a tierra. Cambios en las condiciones y
el tiempo, pueden dar lugar al deterioro del
aislamiento.

Cables no-blindados conectados a lneas areas
pueden presentar ondas transitorias provocadas por
descargas atmosfricas (relmpagos) o a la
induccin por nubes cargadas elctricamente y/o
nieblas a la deriva. Esto puede dar lugar a picos
transitorios de las tensiones electrostticas y por
ende al deterioro del aislamiento.

Cuando la superficie externa del aislamiento o la
cubierta aislante del cable no est en contacto con
tierra a todo lo largo de la longitud del cable (cable
no-blindado), una diferencia de potencial
considerable puede presentarse entre la cubierta y
tierra.

Esta diferencia de potencial puede crear un riesgo y
podra ser mortal para cualquier persona que entra
en contacto con el cable y podra tambin dar lugar
a chispas que podran ser una fuente de ignicin
para mezclas de gases explosivos.

El blindar un cable de energa elctrica es poner en
practica la confinacin de su campo dielctrico al
interior del aislamiento del cable circundando el
aislamiento con un medio conductor puesto a tierra
llamado blindaje (pantalla).

Algunos medios conductores idneos para su uso en
blindajes son: cintas de metal, trenzas de metal,
tubos metlicos, cintas semiconductoras, capas
semiconductoras extruidas y capas semiconductoras
extruidas sobre filamentos de alambre.

La pantalla acta como barrera a las tensiones
electrostticas y las confina al aislamiento.

El blindaje correctamente aplicado y puesto a tierra
incrementa la eficacia del aislamiento.

mantendr una distribucin homognea de las
tensiones radiales dentro del aislamiento.

eliminara las tensiones tangenciales.

El blindaje correctamente aplicado y puesto a tierra,
eliminara las tensiones longitudinales en toda la
superficie del aislamiento homologndola con
tierra.

atenuara las transitorias en los cables conectados a
lneas areas.

proporciona seguridad al personal.

ayuda a eliminar las fuentes de ignicin debidas a
las chispas por descarga.
Los ingenieros de AmerCable recomiendan que todos los cables sobre los 4160 voltios sean blindados y,
dependiendo del ambiente operacional, considerar concienzudamente el blindar los cables de arrastre
para voltajes mayores a los 2000 voltios.

Adaptacin libre por Sergio J . Rodriguez M., Ausproof Pty. Ltd., del original Why you should shield high voltage trailing cables. J ulio 18, 2006.
No-Blindado vs. Blindado
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Application Note
Insulation Resistance
Testing
Introduction
Insulation resistance testers can
be used to determine the integ-
rity of windings or cables in
motors, transformers, switch-
gear, and electrical installations.
The test method is determined
by the type of equipment being
tested and the reason for test-
ing. For instance, when testing
electrical cabling or switchgear
(low-capacitance equipment)
the time-dependent capacitive
leakage and absorption leakage
currents become insignificant
and decrease to zero almost
instantly. A steady conductive
leakage current flow is reached
almost instantly (a minute or
less) providing perfect condi-
tions for the spot-reading/short-
time resistance test. (For more
detailed information on leakage
currents and resistance tests see
the following sections: What Is
Insulation Resistance & Leak-
age Currents and Predictive
Maintenance Tests).
On the other hand, when the
equipment to be tested is a long
run of cable, large motor, or
generator (high-capacitance
equipment) the time-dependent
currents will last for hours.
These currents will cause the
meter readings to change con-
stantly, making it impossible to
obtain an accurate steady read-
ing. This condition can be
overcome by using a test that
establishes a trend between
readings, such as the step volt-
age or dielectric-absorption test.
These tests do not depend on a
single reading but on a collec-
tion of relative readings. It
would be a waste of time to
perform these tests on low-
capacitance equipment since
the time-dependent currents
diminish quickly, resulting in all
the measurements being the
same.
Installation testing
The most important reason for
testing insulation is to insure
public and personal safety. By
performing a high dc voltage
test between de-energized cur-
rent-carrying (hot), grounded,
and grounding conductors, you
can eliminate the possibility of
having a life-threatening short
circuit or short to ground. This
test is usually performed after
the initial installation of the
equipment. This process will
protect the system against
miswired and defective equip-
ment, and it will insure a high
quality installation, customer
satisfaction, and protect against
fire or shock.
Maintenance testing
The second most important
reason for insulation testing is
to protect and prolong the life
of electrical systems and motors.
Over the years, electrical sys-
tems are exposed to environ-
mental factors such as dirt,
grease, temperature, stress, and
vibration. These conditions can
lead to insulation failure, result-
ing in loss of production or even
fires. Periodic maintenance tests
can provide valuable informa-
tion about the state of deteriora-
tion and will help in predicting
possible failure of the system.
Correcting problems will result
not only in a trouble-free sys-
tem, but will also extend the
operating life for a variety of
equipment.
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2 Fluke Corporation Insulation Resistance Testing
Work safely
Safety is everyones responsi-
bility, but ultimately it is in your
hands. No tool by itself can
guarantee your safety. It is the
combination of the instrument
and safe work practices that
gives you maximum protection.
Here are a few safety tips you
should follow:
Work on de-energized circuits

whenever possible.
Use proper lock-out/tag-out
procedures. If these proce-
dures are not in place or not
enforced, assume the circuit
is live.
On live circuits, use protective

gear:
Use insulated tools
Wear flame resistant

clothing, safety glasses,
and insulation gloves
Remove watches or other

jewelry
Stand on an insulation
mat
When making voltage mea-

surements on live circuits:
Hook on the ground clip

first, then make contact
with the hot lead. Remove
the hot lead first and the
ground lead last.
Hang or rest the meter if

possible. Try to avoid hold-
ing it in your hands to
minimize personal
exposure to the effects of
transients.
Use the three-point test

method, especially when
checking to see if a circuit
is dead. First, test a known
live circuit. Second, test
the target circuit. Third,
test a live circuit again.
This verifies that your
meter worked properly
before and after the mea-
surement.
Use the old electricians

trick of keeping one hand
in your pocket. This less-
ens the chance of a closed
circuit across your chest
and through your heart.
When performing insulation

and resistance tests:
Never connect the insula-

tion tester to energized
conductors or energized
equipment and always
follow the manufacturers
recommendations.
Before measuring
In order to obtain meaningful
insulation resistance measure-
ments, the electrician should
carefully examine the system
under test. The best results are
achieved when:
1. The system or equipment is
taken out of service and
disconnected from all other
circuits, switches, capacitors,
brushes, lightning arrestors,
and circuit breakers. Make
sure that the measurements
are not affected by leakage
current through switches
and overcurrent protective
devices.
2. The temperature of the con-
ductor is above the dew
point of the ambient air.
When this is not the case, a
moisture coating will form on
Shut down the equipment

to be tested by opening
fuses, switches, and circuit
breakers.
Disconnect the branch

circuit conductors,
grounded conductors,
grounding conductors, and
all other equipment from
the unit under test.
Discharge conductor
capacitance, both before
and after the test. Some
instruments may have
automatic discharge
functions.
Check for any leakage

current through fuses,
switches, and breakers on
de-energized circuits.
Leakage current can cause
inconsistent and incorrect
readings.
Dont use an insulation

tester in a dangerous or
explosive atmosphere
since the instrument can
generate arcing in dam-
aged insulation.
Use insulated rubber

gloves when connecting
the test leads.
the insulation surface, and, in
some cases will be absorbed
by the material.
3. The surface of the conductor
is free of carbon and other
foreign matter that can be-
come conductive in humid
conditions.
4. Applied voltage is not too
high. When testing low-
voltage systems; too much
voltage can overstress or
damage insulation.
5. The system under test has
been completely discharged
to the ground. The grounding
discharge time should be
about five times the testing
charge time.
6. The effect of temperature is
considered. Since insulation
resistance is inversely propor-
tional to insulation tempera-
ture (resistance goes down as
temperature goes up), the
recorded readings are altered
by changes in the temperature
of the insulating material. It is
recommended that tests be
performed at a standard con-
ductor temperature of 20C
(68F). As a rule of thumb,
when comparing readings to
20C base temperature,
double the resistance for ev-
ery 10C (18F) above 20C or
halve the resistance for every
10C below 20C in tempera-
ture. For example, a one-me-
gohm resistance at 40C
(104F) will translate to four-
megohm resistance at 20C
(68). To measure the conduc-
tor temperature, use a non-
contact infrared thermometer
such as the Fluke 65.
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Insulation Resistance Testing Fluke Corporation 3
What are insulation
resistance and
leakage currents?
During the testing procedure,
the high dc voltage generated
by pressing the test button will
cause a small (micro-amps)
current flow through the con-
ductor and the insulation. The
amount of current depends on
the amount of voltage applied,
the systems capacitance, the
total resistance, and the tem-
perature of the material. For a
fixed voltage, the higher the
current, the lower the resistance
(E=IR, R=E/I). The total resis-
tance is the sum of the internal
resistance of the conductor
(small value) plus the insulation
resistance in Ms.
Figure 1. Current components
Total Current
(I
A
+ I
C
+ I
L
)
Time
(in seconds)
0
Current
(in A)
Insulation
Resistance
(in Megohms)
I
L
I
C
I
A
Figure 2. Conductive leakage current (I
L
)
I
L
Conductors
Dielectric
Insulation
Figure 3. Capacitive charging leakage current (I
C
)
I
C
Conductors
Dielectric
Insulation
The value of insulation resis-
tance read on the meter will be
a function of following three
independent sub-currents.
Conductive leakage
current (I
L
)
Conductive current is a small
(micro-amp) amount of current
that normally flows through
insulation, between conductors
or from a conductor to ground.
This current increases as insula-
tion deteriorates and becomes
predominant after the absorp-
tion current (see Figure 1) van-
ishes. Because it is fairly steady
and time independent, this is
the most important current for
measuring insulation resistance.
Capacitive charging leakage
current (I
C
)
When two or more conductors
are run together in a raceway,
they act as a capacitor. Due to
this capacitive effect, a leakage
current flows through conductor
insulation. This current lasts
only for a few seconds as the dc
voltage is applied and drops out
after the insulation has been
charged to its full test voltage.
In low-capacitance equipment,
the capacitive current is higher
than conductive leakage current,
but usually disappears by the
time we start recording the data.
Because of this, it is important
to let the reading settle out
before recording it. On the other
hand, when testing high capaci-
tance equipment the capacitive
charging leakage current can
last for a very long time before
settling out.
Polarization absorption
leakage current (I
A
)
Absorption current is caused by
the polarization of molecules
within dielectric material. In
low-capacitance equipment, the
current is high for the first few
seconds and decreases slowly
to nearly zero. When dealing
with high capacitance equip-
ment or wet and contaminated
insulation, there will be no de-
crease in the absorption current
for a long time.
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Metal Conduit
Insulation
Applications
Installation test
Proof testing
Electricians and engineers per-
form proof tests to insure proper
installation and integrity of
conductors. The proof test is a
simple, quick test used to indi-
cate the instantaneous condi-
tion of insulation. It provides no
diagnostic data and the test
voltages used are much higher
than the voltages used in pre-
dictive maintenance tests. The
proof test is sometimes called
GO/NO GO TEST because it tests
cable systems for maintenance
errors, incorrect installation,
serious degradation, or contami-
nation. The installation is
declared acceptable if no break-
down occurs during testing.
Choosing the test voltage
A proof test can be performed
on equipment of any capaci-
tance. It is performed with a
single voltage, usually between
500 and 5000 V, for about one
minute. It is common to stress
the insulation above normal
working voltages in order to
detect subtle weaknesses in the
insulation. For new equipment,
the test should be done at about
60% to 80% of the manu-
facturers factory test voltage
(higher than the rated voltage
and is available from the cable
manufacturer). If you dont
know the factory test voltage,
test using a voltage about twice
the cables rated voltage plus
1000 volts. Rated voltage is the
maximum amount of voltage
that the conductor can be ex-
posed to for a prolonged amount
of time, usually printed on the
conductor. For single-phase,
two-phase, or three-phase sys-
tems, the cable is rated phase-
to-phase.
This previously mentioned
method should only be used for
testing small and new appara-
tus because of its ability to
withstand higher stress voltages.
For larger or older equipment or
wire use dc test voltages (see
table 3).
Common proof dc test volt-
ages (not the manufacturers
test voltages) used for testing
rotating equipment are shown
in Table 1.
Table 1. Proof test voltage equations for rotating machines
Proof test procedure
To conduct an installation proof
test, use the following procedure:
Use a multimeter or the volt-

age measurement function on
the MegOhmMeter to make
sure there is no power applied
to the tested circuit.
Select the appropriate voltage

level.
Plug one end of the black test

lead to the common terminal
on the meter and touch the
test probe to a ground (earth)
or another conductor. Some-
times it is helpful to ground all
conductors that are not part of
the test. Alligator clips can
make measurements easier
and more accurate.
Plug one end of the red test

lead to the volt/ohm terminal
on the meter and connect the
test probe to the conductor to
be tested.
Press the test button to apply

Figure 4. Conductor under test
Rotating Equipment DC Test Voltages Formula Used
Factory AC Test, VAC (only for reference) 2 x (VAC Nameplate Rating) + 1,000
Maximum DC Installation Test, VDC 1.28 x (Factory AC Test)
Maximum DC After Service Test, VDC 0.96 x (Factory AC Test)
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the desired voltage and read
the resistance displayed on
the meter. It could take a few
seconds for the reading to
settle. The higher the resis-
tance is the better.
Test each conductor against

ground and against all the
other conductors present in
the conduit. Keep a dated
record of the measured values
in a safe place.
If some of the conductors fail

the test, identify the problem
or re-pull the conductors.
Moisture, water, or dirt can
create low resistance readings.
Predictive maintenance
tests
Maintenance tests can provide
important information about
the present and future state of
conductors, generators, trans-
formers, and motors. The key to
effective maintenance testing is
good data collection. Examining
the collected data will aid in
scheduling diagnostic and
repair work, which will reduce
downtime from unexpected fail-
ures. The following are the
most commonly applied dc test
voltages and maintenance tests
performed:
Table 2. Maintenance test voltages versus
equipment ratings
Spot-reading/short-time
resistance test
During the short-time test, the
MegOhmMeter is connected
directly across the equipment
being tested and a test voltage
is applied for about 60 seconds.
In order to reach a stable insu-
lation reading in about one
minute, the test should only be
performed on low-capacitance
equipment. The basic connec-
tion procedure is the same as
for a proof test and the voltage
applied is calculated from the dc
test voltage formulas. When
testing good equipment, you
Table 3. DC test voltage equations
should notice a steady increase
in insulation resistance due to
decrease in capacitive and ab-
sorption currents. Because tem-
perature and humidity can af-
fect the readings, the
measurements should prefer-
ably be made above the dew
point at standard temperature,
about 20C/68F.
For equipment rated at or
below 1000 volts, the insulation
reading should be of a value of
1M or greater. For equipment
rated above 1000 volts, the
expected resistance should in-
crease to one megohm per 1000
volts applied. Usually, the mea-
sured insulation resistance will
be a bit less than the values
recorded previously, resulting in
a gradual downward trend as
Figure 5. Insulation resistance test
DCt - dc test voltage related to
the maximum insulation
stress during normal ac
operation
E
p-p
- Phase-to-phase voltage
rating
E
p-n
- Phase-to-ground voltage
rating
0 60 sec Time
(in seconds)
Resistance
(in Megohms)
Recorded Value
(in Megohms)
Figure 6. Insulation resistance over a period of time
1995 1996 1997 1998 1999 2000
Year
1000
500
100
50
10
5
Initial
Acceptance
Test
Aging
of
Insulation
After
Rewinding
Insulation
Failure
Resistance
(in Megohms)
shown in Figure 6. The down-
ward slope is a normal sign of
insulation aging. A sharp down-
ward slope would indicate an
insulation failure or a warning
of troubles ahead.
DC Test Voltages Formula Used
For phase-to-phase DCt = 0.8165 x E
p-p
voltage rating
For phase-to-ground DCt = 1.414 x E
p-n
voltage rating
Equipment DC Test Voltage
AC Rating (Volts) (Volts)
0 100 100 250
440 560 500 1,000
2,300 1,000 or higher
4,100 and above 1,000 or higher
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0 60 sec Time
(in seconds)
Resistance
(in Megohms)
Direction of
Insulation
Failure
Test Made
with 250V
Test Made
with 500V
Test Made
with 1000V
Figure 7. Step voltage test
Figure 8. Good and poor test curves
Figure 9. Dielectric absorption test for good and contaminated curves
Voltage
(in kV)
1000
500
100
50
10
5
Good
Insulation
Condition
Poor
Insulation
Condition
Resistance
(in Megohms)
Step voltage test
The step voltage test involves
resistance testing at various
voltage settings. In this test, you
apply each test voltage for the
same period of time (usually 60
seconds), graphing the recorded
insulation resistance. By apply-
ing increasing voltages in steps,
the insulation is exposed to in-
creased electrical stress that can
reveal information about flaws
in the insulation such as pin-
holes, physical damage, or
brittleness. Good insulation
should withstand an increase in
over-voltage stress and its resis-
tance should remain approxi-
mately the same during testing
with different voltage levels. On
the other hand, especially at
higher voltage levels, deterio-
rated, cracked or contaminated
insulation will experience an
increased current flow, resulting
in a decrease in insulation resis-
tance. This test is independent
of insulation material, equipment
capacitance, and temperature
effect. Because it takes a longer
time to run, it should be per-
formed only after an insulation
spot test has been inconclusive.
A spot test deals with absolute
resistance change (single read-
ing) with respect to time, while
the step voltage test looks for
trends in resistance, with re-
spect to varying test voltages.
Dielectric-absorption/
time-resistance test
The time resistance test is
independent of equipment size
and temperature. It compares
the absorption characteristics of
contaminated insulation with the
absorption characteristics of good
insulation. The test voltage is
applied over a 10 minute period,
with the data recorded every 10
seconds for the first minute and
then every minute thereafter.
The interpretation of the slope of
the plotted graph will determine
the condition of the insulation. A
continuous increase in graphed
resistance indicates good insula-
tion. A flat or downward curve
indicates cracked or contami-
nated insulation.
0 10 min Time
(in minutes)
Resistance
(in Megohms)
Good
Insulation
Cracked
Insulation
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Another method for deter-
mining the quality of insulation
is to use the polarization index
(PI) test. It is particularly valu-
able for uncovering moisture
and oil ingress that have a flat-
tening effect on the PI curve,
causing leakage current and
eventually shorted windings.
The polarization index is the
ratio of two time-resistance
readings: one is taken after 1
minute and the other is taken
after 10 minutes. With good
insulation, the insulation resis-
tance will start low and get
higher as the capacitive leakage
current and absorption current
get smaller. Results are obtained
by dividing the 10 minute test
value by the one-minute test
value. A low polarization index
usually indicates problems with
the insulation. When test time is
constrained, a shortcut to the
polarization index test is the
dielectric absorption ratio
(60/30) second test.
Testing connections
in generators,
transformers,
motors, and wiring
To test the insulation resistance
in generators, transformers,
motors, and wiring installations,
we can employ any of the pre-
viously mentioned predictive
maintenance tests. Whether we
choose the spot-reading, step
voltage, or time-resistance tests
depends on the reason for test-
ing and the validity of the data
obtained. When testing genera-
tors, motors, or transformers
each winding/phase should be
tested in sequence and sepa-
rately while all the other wind-
ings are grounded. In this way,
the insulation between phases
is also tested.
Temperature correction for
testing rotating machines
For testing armature and field
winding insulation resistance at
various temperatures, the IEEE
recommends the following insu-
lation resistance formula.
Table 4. Approximate dielectric absorption ratios
Rm - Minimum insulation resis-
tance corrected to 40C
(104F) in M
Kt - Insulation resistance
temperature coefficient at
winding temperature,
obtained from Figure 10
kV - Rated machine terminal
to terminal voltage in
kilovolts
Table 5. Various insulation tests
Rm = Kt x (kV + 1)
Table 6. Insulation resistance equation for ac
and dc rotating machinery
100
50
10
5
1.0
0.5
0.1
0.05
-10 0 10 20 30 40 50 60 70 80 90 100
Winding Temperature, Degrees Celsius
I
n
s
u
l
a
t
i
o
n

R
e
s
i
s
t
a
n
c
e

T
e
m
p
e
r
a
t
u
r
e

C
o
e
f
f
i
c
i
e
n
t
,

K
t
For a three phase system tested
with the other two phases
grounded, the resistance re-
corded for each phase should
be divided by two. Then, the
resulting value can be com-
pared with the recommended
minimum insulation resistance
(Rm).
Figure 10. Approximate temperature coefficient for rotating machines
Proof Test Spot- Test Step Test Dielectric- Polarization
Reading Voltage Absorption Index Test
Test
Single reading

High test voltage
Performed

periodically
Various test
voltages
Timed test

intervals
Diagnostic

information
Insulation Resistance 60/30 Second Ratio 10/1 Minute Ratio
Condition (Polarization Index)
Dangerous 0 -1.0 0 - 1
Poor 1.0 1.3 1 2
Good 1.3 1.6 2 4
Excellent 1.6 and above 4 and above
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Fluke Corporation
PO Box 9090, Everett, WA USA 98206
Fluke Europe B.V.
PO Box 1186, 5602 BD
Eindhoven, The Netherlands
For more information call:
U.S.A. (800) 443-5853 or
Fax (425) 356-5116
Europe/M-East/Africa (31 40) 2 675 200 or
Fax (31 40) 2 675 222
Canada (800) 36-FLUKE or
Fax (905) 890-6866
Other countries (425) 356-5500 or
Fax (425) 356-5116
Web access: http://www.fluke.com
2001 Fluke Corporation. All rights reserved.
Printed in The Netherlands 3/2001
10307-ENG
Rev. 01.
Microsoft and Windows are registered trademarks of
Microsoft Corporation.
Printed on recycled paper.
Fluke. Keeping your world
up and running.
Figure 11. Testing the insulation resistance of a motor
To Ground
To Different
Windings
Fluke 1520
MegOhmMeter
Table 7. Recommended minimum resistance at
40C (104F)
Table 8. Transformers insulation resistance
equations
Table 9. Constant C values at 20C (68)
Testing generators and
motors
When testing the resistance of
the stator coils make sure the
stator winding and phases are
disconnected. Measure the insu-
lation resistance between
windings and windings to
ground. Also, when dc genera-
tors or motors are being tested
the brushes should be raised so
the coils can be tested sepa-
rately from the armature. The
following table lists recom-
mended minimum resistance
readings for various motor volt-
age ratings.
Testing transformers
When testing single-phase
transformers, test winding to
winding, winding to ground, or
test one winding at a time with
all others grounded. For three-
phase transformers, substitute E
with EP-P (for delta transformers)
or E
p-n
(for wye transformers)
and kVA with kVA
3
rating of the
winding under test.
For determining minimum
insulation resistance use the
following formula.
R = K x Log10 (D/d)
Table 10. Cable insulation resistance
Testing wiring and cable
installations
When testing wires or cables,
they should be disconnected
from panels and machinery to
keep them isolated. The wires
and cables should be tested
against each other and against
ground (see Figure 4 on page
4). The Insulated Power Cable
Engineers Association (IPCEA)
provides the following formula
that suggests minimum insula-
tion resistance values.
R - Ms per 1000 feet (305
meters) of cable. Based on
dc test potential of 500
volts, applied for one
minute at 15.6C (60F)
temperature)
K - Insulation material constant.
(For example: Impregnated
Paper-2640, Varnished
Cambric-2460, Thermoplas-
tic Polyethlene-50000,
Composite Polyethylene-
30000)
D - Outside diameter of conduc-
tor insulation for single
conductor wire and cable
D = d + 2c + 2b diameter
of single conductor cable
d - Diameter of conductor
c - Thickness of conductor
insulation
b - Thickness of jacket
insulation
For example, one thousand
feet of number 6 A.W.G. Heat
Resistant Natural Rubber insula-
tion type stranded conductor
with 0.125 insulation thickness
will have K = 10,560 and Log10
(D/d) = 0.373 inches. According
to the formula (R = K x Log10
(D/d), R = 10,560 x 0.373 =
3,939 M per 1000 feet) the
expected minimum insulation
resistance for single conductor
per thousand feet at tempera-
ture of 60F will be 3,939 M.
R - One minute 500 volt dc
minimum insulation
resistance in megohms
C - Constant for 20C (68)
measurements
(see below)
E - Winding voltage rating.
KVA - Rated capacity of wind-
ing under test. For three
phase units kVA
3
=
3 x kVA
1
Transformer Type Formula Used
Single phase R = C x E kVA
Three phase wye R = C x E
p-n
kVA
Three phase delta R = C x E
p-p
kVA
Motor Nameplate Minimum Acceptable
Voltage Rating Resistance
0-208 100,000
208-240 200,000
240-600 300,000
600-1000 1 M
1000-2400 2 M
2400-5000 3 M
Transformer Type 60-Hertz
Tanked oil-filled type 1.5
Untanked oil-filled type 30.0
Dry or compound-filled type 30.0
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PREFACIO

Incrementar las horas operativas

Disminuir los actos inseguros.

os con o sin perdidas.

Facilitando equipamiento, maquinas y

rgicas con la actividad.

Realizando procedimientos e instruyendo

EPP especifico requerido.

Etapas requeridas para un

Desarrollo de procedimientos y obtenci

Entrenamiento anual y seguimiento.

Work on de-energized circuits

On live circuits, use protective

Use insulated tools

Wear flame resistant

Remove watches or other

When making voltage mea-

Hook on the ground clip

Hang or rest the meter if

Use the three-point test

Use the old electricians

When performing insulation

Never connect the insula-

Shut down the equipment

Disconnect the branch

Check for any leakage

Dont use an insulation

Use insulated rubber

Use a multimeter or the volt-

Select the appropriate voltage

Plug one end of the black test

Plug one end of the red test

Press the test button to apply

Test each conductor against

If some of the conductors fail

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